Absorbent article having an anchored core assembly

ABSTRACT

Embodiments of the present disclosure include disposable wearable absorbent articles with anchoring systems. In an embodiment, a disposable wearable absorbent article includes an absorbent core with an absorbent core end, an anchoring system configured to anchor the absorbent core to a wearer, and a waist cover that covers at least a portion of the absorbent core end.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.11/599,862, filed on Nov. 15, 2006, which claims the benefit of U.S.Provisional Application No. 60/811,580, filed Jun. 7, 2006, both ofwhich are hereby incorporated by reference. This application also claimsthe benefit of U.S. Provisional Application No. 60/811,580, filed Jun.7, 2006.

FIELD OF INVENTION

This invention relates to absorbent articles generally, and inparticular relates to an absorbent article having an absorbent core andan anchoring system that supports the core assembly of the absorbentarticle.

BACKGROUND OF THE INVENTION

It has long been known that absorbent articles such as conventionaltaped diapers, pull-on diapers, training pants, incontinence briefs, andthe like, offer the benefit of receiving and containing urine and/orother bodily exudates. Such absorbent articles can include a chassisthat defines a waist opening and a pair of leg openings. A pair ofbarrier leg cuffs can extend from the chassis toward the wearer adjacentthe leg openings, thereby forming a seal with the wearer's body toimprove containment of liquids and other body exudates. Conventionalchassis include a core that is disposed between a topsheet and agarment-facing outer cover (also known as a backsheet).

The outer cover can include a stretchable waistband at one or both ofits ends (e.g., proximal opposing laterally extending edges),stretchable leg bands surrounding the leg openings, and stretchable sidepanels, which can be integral or separate discrete elements attacheddirectly or indirectly to the outer cover. The remainder of the outercover typically comprises a non-stretchable nonwoven-breathable filmlaminate. Unfortunately, such diapers do not conform well to thewearer's body during different body movements, e.g. sitting, standing,and walking due to the relative anatomic dimensional changes (which can,in some instances, be up to 50%) in the buttocks region caused by thesemovements. This problem is further exacerbated by the fact that onediaper typically has to fit all the wearers in a given size range.

The dimensions of the smallest and biggest wearers within a given sizerange can be markedly different. For instance the waist circumference atthe navel can vary by 80 mm within a given size range. Also, thenavel-to-back distance, which is the distance from the navel, throughthe crotch, and to a point on the back of the wearer that is in the samehorizontal plane as the navel, can vary by about 80 mm from the smallestto the largest wearers in this same size.

In addition, it has been determined that caregivers and wearers preferthe look and feel of cotton underwear (not provided by conventionaldisposable diapers) for several reasons. For instance, cotton underwearinclude elastic waist and leg bands that encircle the waist and legregions of the wearer and provide forces that keep the underwear on thewearer's body. Furthermore, the cotton outer cover (except in the waistand leg bands) can be stretched along the width and length directions inresponse to a relatively low force to accommodate the anatomicdimensional differences related to movement and different wearerpositions. The stretched portion returns back to substantially itsoriginal dimension once the applied force is removed. In other words,the cotton outer cover of the underwear has low-force, recoverablebiaxial stretch that provides a conforming fit to a wider array ofwearer sizes than conventional diapers.

An effort has therefore begun to develop diapers that simulate the lookand feel of traditional cotton underwear. However, diapers, unlikecotton underwear, are designed to receive and retain loads (i.e., bodilyexudates) that are received during use while minimizing or eliminatingleakage. It has been found that the downward forces resulting from theseloads cause biaxially stretchable outer covers from the prior art tosag, droop, or otherwise distend to the detriment of the fit of thediaper on the wearer. Sagging is generally unsightly, and can causeleakage of the bodily exudates due to, for example, displacement of thebarrier leg cuffs away from the wearer's body.

What is therefore needed is an absorbent article including an anchoringsystem which is capable of supporting the core assembly therebysupporting the (downward) force(s) exerted by the core assembly.Additionally, what is needed is an absorbent article capable ofincluding a bi-axially stretchable outer cover while minimizingoccurrences of sagging of the outer cover and leakage during use.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is hereby made to the following figures in which likereference numerals correspond to like elements throughout, and in which:

FIG. 1A illustrates a plan view of an embodiment of a disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 1B illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 1A, according to the present disclosure.

FIG. 1C illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 1A, according to the present disclosure.

FIG. 2A illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 2B illustrates a front view of the anchoring system and absorbentcore of FIG. 2A, according to the present disclosure.

FIG. 2C illustrates a back view of the anchoring system and absorbentcore of FIG. 2A, according to the present disclosure.

FIG. 3A illustrates a plan view of an embodiment of anchoring bandsattached to an absorbent core, according to the present disclosure.

FIG. 3B illustrates a plan view of an embodiment of anchoring bandsattached to an absorbent core, according to the present disclosure.

FIG. 4A illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 4B illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 4C illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 5A illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 5B illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 6 illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 7A illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 7B illustrates a perspective view of an embodiment of an anchoringsystem joined to an absorbent core, for use in a disposable absorbentarticle, according to the present disclosure.

FIG. 8 illustrates a plan view of an embodiment of an anchoring systemintegrally formed into to an outer cover, for use in a disposableabsorbent article, according to the present disclosure.

FIG. 9 illustrates a side view of an embodiment of an absorbent articleas worn on a wearer, according to the present disclosure.

FIG. 10 illustrates a perspective view of an embodiment of package ofabsorbent articles, according to the present disclosure.

FIG. 11 illustrates a plan view of an embodiment of disposable absorbentarticle with an absorbent core, an anchoring system, and a waist cover,according to the present disclosure.

FIG. 12A illustrates a plan view of an embodiment of disposableabsorbent article with an absorbent core, an anchoring system, and awaist cover, according to the present disclosure.

FIG. 12B illustrates a plan view of an embodiment of disposableabsorbent article with a carrier web for core end management, accordingto the present disclosure.

FIG. 12C illustrates a plan view of an embodiment of disposableabsorbent article with an activated topsheet for core end management,according to the present disclosure.

FIG. 13A illustrates a plan view of an embodiment of disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 13B illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 13A, according to the present disclosure.

FIG. 13C illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 13A, according to the present disclosure.

FIG. 13D illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 13A, according to the present disclosure.

FIG. 13E illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 13A, according to the present disclosure.

FIG. 14 illustrates a plan view of an embodiment of disposable absorbentarticle with an absorbent core and an anchoring system, according to thepresent disclosure.

FIG. 15A illustrates a plan view of an embodiment of disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 15B illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 15A, according to the present disclosure.

FIG. 15C illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 15A, according to the present disclosure.

FIG. 15D illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 15A, according to the present disclosure.

FIG. 15E illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 15A, according to the present disclosure.

FIG. 15F illustrates an embodiment of elements of an anchoring systemfor use in a disposable absorbent article, according to the presentdisclosure.

FIG. 15G illustrates an embodiment of elements of an anchoring systemfor use in a disposable absorbent article, according to the presentdisclosure.

FIG. 16 illustrates a plan view of an embodiment of a disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 17 illustrates a plan view of an embodiment of a disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 18 illustrates a plan view of an embodiment of a disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 19A illustrates a plan view of an embodiment of a disposableabsorbent article with an absorbent core and an anchoring system,according to the present disclosure.

FIG. 19B illustrates a cross-sectional view of the disposable absorbentarticle of FIG. 19A, according to the present disclosure.

FIG. 20A illustrates a plan view of an embodiment of disposableabsorbent article with an anchoring system, including a stretchableportion, according to the present disclosure.

FIG. 20B illustrates a plan view of an embodiment of disposableabsorbent article with an anchoring system, including a stretchableportion, according to the present disclosure.

FIG. 20C illustrates a plan view of an embodiment of disposableabsorbent article with an anchoring system, including a stretchableportion, according to the present disclosure.

FIG. 21 illustrates a perspective view of a portion of a human bodyalong with a coordinate system.

FIG. 22 illustrates a perspective view of a human body with forcevectors relating to an anchoring system for a disposable absorbentarticle, according to the present disclosure.

FIG. 23 illustrates another perspective view of a human body with forcevectors relating to an anchoring system for a disposable absorbentarticle, according to the present disclosure.

FIG. 24A illustrates a perspective view of a human body with forcevectors relating to a particular embodiment of an anchoring system for adisposable absorbent article, according to the present disclosure.

FIG. 24B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 24A, according to the present disclosure.

FIG. 24C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 24B, according to the presentdisclosure.

FIG. 25A illustrates a perspective view of a human body with forcevectors relating to another particular embodiment of an anchoring systemfor a disposable absorbent article, according to the present disclosure.

FIG. 25B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 25A, according to the present disclosure.

FIG. 25C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 25B, according to the presentdisclosure.

FIG. 26A illustrates a perspective view of a human body with forcevectors relating to yet another particular embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 26B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 26A, according to the present disclosure.

FIG. 26C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 26B, according to the presentdisclosure.

FIG. 27 illustrates a perspective view of an embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 28A illustrates a perspective view of a human body with forcevectors relating to still another particular embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 28B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 28A, according to the present disclosure.

FIG. 28C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 28B, according to the presentdisclosure.

FIG. 29A illustrates a perspective view of a human body with forcevectors relating to a further particular embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 29B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 29A, according to the present disclosure.

FIG. 29C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 29B, according to the presentdisclosure.

FIG. 30A illustrates a perspective view of a human body with forcevectors relating to a still further particular embodiment of ananchoring system for a disposable absorbent article, according to thepresent disclosure.

FIG. 30B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 30A, according to the present disclosure.

FIG. 30C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 30B, according to the presentdisclosure.

FIG. 31A illustrates a perspective view of a human body with forcevectors relating to a yet further particular embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 31B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 31A, according to the present disclosure.

FIG. 31C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 31B, according to the presentdisclosure.

FIG. 32A illustrates a perspective view of a human body with forcevectors relating to an additional particular embodiment of an anchoringsystem for a disposable absorbent article, according to the presentdisclosure.

FIG. 32B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 32A, according to the present disclosure.

FIG. 32C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 32B, according to the presentdisclosure.

FIG. 33A illustrates a perspective view of a human body with forcevectors relating to another additional particular embodiment of ananchoring system for a disposable absorbent article, according to thepresent disclosure.

FIG. 33B illustrates a perspective view of the anchoring system for theforce vectors of FIG. 33A, according to the present disclosure.

FIG. 33C illustrates a perspective view of the disposable absorbentarticle for the anchoring system of FIG. 33B, according to the presentdisclosure.

FIG. 34 illustrates a top view of force vectors relating to anembodiment of an anchoring system for a disposable absorbent article,according to the present disclosure.

FIG. 35 illustrates a top view of force vectors relating to anembodiment of an anchoring system for a disposable absorbent article,according to the present disclosure.

FIG. 36 illustrates a portion of an element of an anchoring system,according to embodiments of the present disclosure.

FIG. 37 illustrates a force band with a point load, according toembodiments of the present disclosure.

FIG. 38 illustrates a force band with two point loads, according toembodiments of the present disclosure.

FIG. 39 illustrates a force band with a distributed load, according toembodiments of the present disclosure.

FIG. 40 illustrates another portion of an element of an anchoringsystem, according to embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION DEFINITIONS

As used herein, the following terms shall have the meaning specifiedthereafter:

The term “disposable,” as used herein in reference to absorbentarticles, means that the absorbent articles are generally not intendedto be laundered or otherwise restored or reused as absorbent articles(i.e., they are intended to be discarded after a single use and,preferably, to be recycled, composted or otherwise discarded in anenvironmentally compatible manner).

The term “absorbent article” as used herein refers to devices whichabsorb and contain body exudates and, more specifically, refers todevices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. Exemplary absorbent articles include diapers, training pants,pull-on pant-type diapers (i.e., a diaper having a pre-formed waistopening and leg openings such as illustrated in U.S. Pat. No.6,120,487), refastenable diapers or pant-type diapers, incontinencebriefs and undergarments, diaper holders and liners, feminine hygienegarments such as panty liners, absorbent inserts, and the like.

The term “diaper” as used herein refers to an absorbent articlegenerally worn by infants and incontinent persons about the lower torsoso as to encircle the waist and legs of the wearer and that isspecifically adapted to receive and contain urinary and fecal waste. Asused herein, term “diaper” also includes “pants” which is defined below.

The terms “proximal” and “distal” as used herein refer respectively tothe location of an element relatively near to or far from the center ofa structure (e.g., the proximal edge of a longitudinally extendingelement is located nearer to the longitudinal axis than the distal edgeof the same element is located relative to the same longitudinal axis).

The terms “body-facing”, “inner-facing”, “outer-facing”, and“garment-facing” as used herein refer respectively to the relativelocation of an element or a surface of an element or group of elements.“Body-facing” and “inner-facing” imply the element or surface is nearerto the wearer during wear. “Garment-facing” and “outer-facing” imply theelement or surface is more remote from the wearer during wear (i.e.,element or surface is nearer to the wearer's garments that can be wornover the disposable absorbent article).

The term “longitudinal” as used herein refers to a direction runningsubstantially perpendicular from a waist edge to an opposing waist edgeof the article and generally parallel to the maximum linear dimension ofthe article. Directions within 45 degrees of the longitudinal directionare considered to be “longitudinal.”

The term “lateral” as used herein refers to a direction running from alongitudinal edge to an opposing longitudinal edge of the article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

“Longitudinal Centerline” refers to a longitudinal line that can bedrawn through the middle of an absorbent article. For most absorbentarticles, the longitudinal centerline separates the article into twosubstantially symmetrical halves that will fall on the left and righthalves of a wearer during wear.

“Lateral Centerline” refers to a lateral line drawn through the midpointof the longitudinal centerline and perpendicular to the longitudinalcenterline.

The term “disposed” as used herein refers to an element being attachedand positioned in a particular place or position with regard to anotherelement.

“Liquid permeable” and “liquid impermeable” refer to the penetrabilityof materials in the context of the intended usage of disposableabsorbent articles. Specifically, the term “liquid permeable” refers toa layer or a layered structure having pores, openings, and/orinterconnected void spaces that permit liquid water to pass through itsthickness in the absence of a forcing pressure. Conversely, the term“liquid impermeable” refers to a layer or a layered structure throughthe thickness of which liquid water cannot pass in the absence of aforcing pressure. Liquid impermeable materials exhibit a hydrohead of atleast about 5 mbar as measured according to the Hydrostatic Head(Hydrohead) Pressure Test provided below in the Test Methods. However,it may be desirable that a liquid impermeable material exhibit ahydrohead of at least about 10 mbar or about 15 mbar. A layer or alayered structure that is water-impermeable according to this definitionmay be permeable to vapor (i.e., may be “vapor permeable”). Such a vaporpermeable layer or layered structure is commonly known in the art as“breathable.”

As used herein the term “stretchable” refers to materials which canstretch to at least an elongated length of 105% on the upcurve of thehysteresis test at a load of about 400 gm/cm. The term “non-stretchable”refers to materials which cannot stretch to at least 5% on the upcurveof the hysteresis test at a load of about 400 gm/cm.

The terms “elastic” and “elastomeric” as used herein refer to anymaterial that upon application of a biasing force, can stretch to anelongated length of at least about 110%, preferably to 125% of itsrelaxed, original length (i.e. can stretch to 10 percent, preferably 25%more than its original length), without rupture or breakage, and uponrelease of the applied force, recovers at least about 40% of itselongation, preferably recovers at least 60% of its elongation, mostpreferably recovers at least about 80% of its elongation. For example, amaterial that has an initial length of 100 mm can extend at least to 110mm, and upon removal of the force would retract to a length of 106 mm(40% recovery). The term “inelastic” refers herein to any material thatdoes not fall within the definition of “elastic” above.

The term “extensible” as used herein refers to any material that uponapplication of a biasing force, can stretch to an elongated length of atleast about 110%, preferably 125% of its relaxed, original length (i.e.can stretch to 10 percent, preferably 25% more than its originallength), without rupture or breakage, and upon release of the appliedforce, shows little recovery, less than about 40%, preferably less thanabout 20% and more preferably less than about 10% of its elongation.

The terms “outboard” and “inboard” as used herein refer respectively tothe location of an element disposed relatively far from or near to thelongitudinal centerline of the diaper with respect to a second element.For example, if element A is outboard of element B, then element A isfarther from the longitudinal centerline than is element B.

The term “anchoring zone” as used herein refers to an area of contactbetween the diaper and wearer where at least a portion of the load forceis supported by the wearer's body. Multiple anchoring zones can bedesirable to increase diaper support. Once their locations areidentified, they map to corresponding zones in the diaper.

The term “core assembly” as used herein refers to at least an absorbentcore and other optional structures (e.g., barrier cuffs, liquid barrierlayer, storage layer, acquisition layer, distribution layer, etc.) toenhance containment of waste and/or structures to enhance structuralintegrity.

The term “circumference” or “circumferential” as used herein, refers toa closed path on the surface around the torso of the body or around aleg. That path can have a smooth, continuous curvature, or it can have“corners” where the curvature makes an abrupt change, e.g. when the pathpasses through a connection zone with three or more connectingtension-carrying bands.

The term “circumferential anchoring member”, or “CAM”, as used herein,refers to one or more anchoring bands, that form a substantiallycircumferential path (or partial circumferential path) around at least aportion of a wearer that is joined to a core assembly at both ends, forcarrying tension that is substantially in a defined path when the diaperis worn.

The term “force-decoupled” as used herein, refers to a configuration ofan absorbent article where movement of one element or location in anarticle will not create a substantial force on a second given element orlocation. In practice this typically means that any material pathwaythat connects the two elements or locations has enough slack or forceattenuation such that the movement of the first element does not inducesubstantial movement in the second element. In some cases where morethan one pathway exists between the two elements or locations, it may beappropriate to state that all or just particular pathways areforce-decoupled.

The terms “pant”, “training pant”, “pre-closed diaper”, “pre-fasteneddiaper”, “pull-on diaper”, and “pant-like garment” as used herein, referto disposable garments having a waist opening and leg openings designedfor infant or adult wearers. A pant can be configured such that the panthas closed waist and leg openings prior to being donned on the wearer,or the pant can be configured such that the waist is closed and the legopenings formed while on the wearer. A pant may be preformed by anysuitable technique including, but not limited to, joining togetherportions of the article using refastenable and/or non-refastenable bonds(e.g., seam, weld, adhesive, cohesive bond, fastener, etc.). A pant maybe preformed anywhere along the circumference of the article (e.g., sidefastened, front waist fastened, rear waist fastened), or at the crotch.Examples of suitable pants are disclosed in U.S. Pat. No. 5,246,433;U.S. Pat. No. 5,569,234; U.S. Pat. No. 6,120,487; U.S. Pat. No.6,120,489; U.S. Pat. No. 4,940,464; U.S. Pat. No. 5,092,861; U.S. Pat.No. 5,897,545; U.S. Pat. No. 5,957,908; and U.S. Patent Publication No.2003/0233082 A1.

The term “pre-closed” refers to an absorbent article that has beenformed into a pant-like garment prior to packaging such that the enduser receives the article as a pant-like garment that can be directlyapplied to the wearer. The term “pre-closed” also encompasses anabsorbent article that can be closed by the end user and formed into apant-like garment prior to applying the garment to the wearer.

As used herein, the terms “substantially” when referring to aquantitative value are intended to include ±20% of the statedquantitative value.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

Description:

Absorbent articles of the present invention provide an anchoring systemwhich can support the (downward) forces exerted by a core assembly.Additionally, some embodiments of the present invention provide anabsorbent article which includes a stretchable outer cover whilereducing the occurrences of sagging of the outer cover and leakageduring use.

In embodiments of the present disclosure, an absorbent article having ananchoring system, as described herein, can include a stretchable outercover. For example, the outer cover can be a uniaxially stretchableouter cover, configured to stretch in one direction. Also as an example,the outer cover can be a biaxially stretchable outer cover, configuredto stretch in two directions. In various embodiments, the outer covercan be configured as described in US non-provisional patent applicationentitled “Biaxially Stretchable Outer Cover for an Absorbent Article,”filed on Nov. 15, 2006 with Express Mail No. EV916939625 and furtheridentified by attorney docket number 10643, which is hereby incorporatedby reference.

In embodiments of the present disclosure, an absorbent article having ananchoring system, as described herein, can be configured with variousstructures and/or functions as described in US non-provisional patentapplication entitled “Disposable Wearable Absorbent Articles WithAnchoring Systems,” filed on Nov. 15, 2006 with Express Mail No.EV916939648 and further identified by attorney docket number 10628Q,which is hereby incorporated by reference. Also, in embodiments of thepresent disclosure, an absorbent article having an anchoring system, asdescribed herein, can have a wrap and tuck configuration as described inUS non-provisional patent application entitled “Disposable AbsorbentArticle Having a Wrap and Tuck Configuration,” filed on Nov. 15, 2006with Express Mail No. EV916939617 and further identified by attorneydocket number 10644, which is hereby incorporated by reference.

Referring to FIG. 1A, an absorbent article constructed in accordancewith the present invention may comprise, in some embodiments, a diaper20. The diaper 20 may have a longitudinal centerline 100 and a lateralcenterline 110. The diaper 20, which is illustrated in FIG. 1A as apant-like garment, defines an inner surface 50 and an opposing outersurface 52. The inner surface 50 generally includes that portion of thediaper 20 which is positioned adjacent the wearer's body during use(i.e., wearer-facing), while the outer surface 52 generally comprisesthat portion of the diaper 20 which is positioned away from the wearer'sbody (i.e., garment-facing).

The diaper 20, in some embodiments, includes a chassis 21, a coreassembly 23, and an anchoring system 42. The chassis 21 includes afirst, or front, waist region 36, a second, or back, waist region 38opposed to the front waist region 36, and a crotch region 37 locatedbetween the front waist region 36 and the back waist region 38. Thewaist regions 36 and 38 generally comprise those portions of the diaper20 which, when the diaper 20 worn, encircle the waist of the wearer. Thewaist regions 36 and 38 can include elastic elements such that theygather about the waist of the wearer to provide improved fit andcontainment. The crotch region 37 is that portion of the diaper 20which, when the diaper 20 is worn, is generally positioned between thelegs of the wearer.

The outer periphery of the chassis 21 is defined by lateral end edges 56that can be oriented generally parallel to the lateral centerline 110,and by longitudinal side edges 54 that can be oriented generallyparallel to the longitudinal centerline 100 or, for better fit, can becurved or angled, as illustrated, to produce an “hourglass” shapedgarment when viewed in a plan view. In some embodiments, thelongitudinal centerline 100 can bisect the end edges 56 while thelateral centerline 110 can bisect the side edges 54.

In some embodiments, the chassis 21 can comprise an outer cover 24extending between, and defining, the lateral end edges 56 and thelongitudinal end edges 54. The outer cover 24 can advantageously bestretchable in one or more directions, elastic in one or moredirections, preferably biaxially stretchable, and preferably stillbiaxially elastic, thereby enhancing both the comfort of the diaper 20on the wearer and the conformability to the wearer's anatomy duringmovement. In some embodiments, the outer cover 24 may benon-stretchable. The outer cover 24 is discussed further hereafter.

The diaper 20 may further comprise the core assembly 23 which can bepositioned on a wearer-facing surface of the outer cover 24. The coreassembly 23 is the portion of the diaper 20 providing much of theabsorptive and containment function. In some embodiments, it may bedesirable to attach the core assembly 23 to the outer cover 24 in as fewlocations as possible; this can make the outer cover 24 look and feelsofter. However, in order to make the design more tamper-resistant, itmay be useful to attach the core assembly 23 to the outer cover 24 alongat least part, if not all, of the core assembly's periphery; or a smalldistance (about 5-20 mm) inboard of the periphery. For example, the bondarea between the core assembly 23 and the outer cover 24 can be lessthan about 70%, or, as another example, less than about 50%, or, as yetanother example, less than about 20% of the area of the core assembly23.

The core assembly 23 comprises a first portion 1536, a second portion1538, and a third portion 1537. As shown, the first portion 1536 can bedisposed, in part, in the first waist region 36. Similarly, the secondportion 1538 and the third portion 1537 can be disposed, in part, in thesecond waist region 38 and the crotch region 37, respectively.

Embodiments are contemplated where the core assembly 23 is joined to theouter cover in a central region 1553 of the core assembly 23. In someembodiments, the bond area can be between about 1 cm² and about 20 cm²or any individual number within the range. In some embodiments, the coreassembly 23 may be bonded to the outer cover 24 wherein the bond arearesembles a strip extending the substantial length of the core assembly,e.g. being long and narrow.

As shown in FIG. 1B, the absorbent core assembly 23 may include anabsorbent core 26 that can be disposed symmetrically or asymmetricallywith respect to either or both of the longitudinal centerline 100 and/orthe lateral centerline 110. Similarly, the core assembly 23 may bedisposed symmetrically or asymmetrically with respect to either or boththe longitudinal centerline 100 and/or the lateral centerline 110.Referring back to FIG. 1A, the absorbent core 26 and core assembly 23are shown symmetrical with respect to both the longitudinal centerline100 and the lateral centerline 110. The core assembly 23 is discussedfurther hereafter.

As shown in FIG. 1B, in some embodiments, the core assembly 23 maycomprise a topsheet 22 which can have a length and a width dimensionsthat are substantially similar to those of the absorbent core 26, whilethe outer cover 24 has length and width dimensions generally larger thanthose of the absorbent core 26. The outer cover 24 thus forms theperiphery of the diaper 20.

Referring to FIG. 1A, the present invention recognizes that the core 26is capable of absorbing substantial loads during use, and that the fitof conventional diapers can be worsened when the increased weight andresultant (downward) forces exerted on the core (and from the core toother diaper components) can cause the diaper 20 to sag or otherwise bedistended. Accordingly, the diaper 20 constructed in accordance with theprinciples of the present invention includes the anchoring system 42intended to fit to the pelvic region of the wearer's torso region whiledirectly supporting the core assembly 23. As shown, in some embodiments,the anchoring system 42 of the present invention may comprise aplurality of load distribution elements (LDEs) 46 capable of directingthe load forces to at least a portion of the wearer's waist region wherethe forces can be coupled into the wearer's body. As a result, theanchoring system 42 can prevent, or minimize, sagging during wear whilethe side edges and end edges, 54 and 56, respectively, move with theparts of the body (spine/abdomen and legs, respectively) that can moverelative to the pelvis without being too uncomfortable/ creating toomuch pressure for the wearer.

In some embodiments, the anchoring system 42 may include a pair ofanchoring bands that, as used herein, refer to structural elements ofthe anchoring system of sufficient strength to carry the forces involvedin anchoring. Anchoring bands 44′ and 44″ form a first circumferentialanchoring member (CAM) 44A (see FIGS. 2A-2C) when the front and back ofthe diaper are joined at the sides to form a fastened diaper 20. FIGS.2A-2C illustrate side, front, and back, views of the anchoring system 42that forms inside the diaper 20 and independently supports the coreassembly 23 (shown in FIG. 1A) when the diaper 20 is worn. Referringback to FIG. 1A, the anchoring bands 44′ and 44″ are capable of joiningto surround the wearer's body at the lower torso region. As shown, insome embodiments, the anchoring bands 44′ and 44″ can be disposedlongitudinally inboard of an elastic waistband 43 of the diaper 20.

The CAM 44 includes a first anchoring band 44′ extending betweenopposing side edges 54 in the front waist region 36, and a secondanchoring band 44″ extending between opposing side edges 54 in the backwaist region 38. The anchoring bands 44′ and 44″ are disposed at alocation proximal the corresponding end edges 56. In the illustratedembodiment, the first anchoring band 44′ converges from the side edges54 to a midpoint (aligned with the longitudinal centerline 100) that isdisposed further from the end edge 56 in the front waist region 36 thanthe anchoring band 44′ at the side edges 54. The second anchoring band44″ can be slightly curved such that the anchoring band 44″ presents aconvex surface edge with respect to the end edge 56 at the back waistregion 38. As illustrated, the first and second anchoring bands 44′ and44″ may be symmetrical with respect to the longitudinal centerline 100.One skilled in the art will appreciate that anchoring bands 44′ and 44″can either be straight (e.g., extending substantially parallel tolateral centerline 110 or extending straight but along a direction thatintersects the lateral centerline 110), can include more than onestraight section extending along a direction that intersects aneighboring straight section, can include a curved section, or caninclude a combination of curved and straight sections. Furthermore, theanchoring bands 44′ and 44″ can have portions that are convex and/orconcave with respect to the corresponding end edges 56.

As shown in FIGS. 1B-1C, in some embodiments, the CAM 44 can be attachedto the wearer-facing surface of the outer cover 24 via any suitableadhesive or cohesive or any suitable means known in the art. When thediaper 20 is preformed into a pant, the anchoring bands 44′ and 44″ canbe operatively connected via side seams 34 or closure members to formthe continuous circumferential anchoring member 44 that circumscribesthe wearer's lower torso region.

The anchoring system 42, in some embodiments, may further comprise oneor more load distribution element(s) 46 (LDE(s)). For example, as shownin FIG. 1A, a plurality of load distribution elements (LDEs) 46 can beconnected to the core assembly 23 and the anchoring bands 44′ and 44″.The LDEs 46 can be joined to the anchoring bands 44′ and 44″ and thecore assembly 23 at connection zones 48. The anchoring bands 44′ and 44″include one or more connection zones 48 that are joined to the LDEs 46.As illustrated, in some embodiments, the connection zones 48 are thepoints where the LDEs 46 are joined to the CAM 44. As shown, in someembodiments, the CAM 44 may comprise an even number of connection zones48 in the first waist region 36 and in the second waist region 38, e.g.two in the first waist region and two in the second waist region.

In one embodiment illustrated in FIG. 1A, four LDEs 46 may be connectedto the four corresponding corners of the core assembly 23. In theembodiment illustrated in FIGS. 1A-1C and 2A-2C, the LDEs 46 may beconnected to the garment-facing surface of the core assembly 23 via anysuitable adhesive, cohesive, thermal bonds, RF bonds, pressure bonds,ultrasonic bonds, welds, stitches, or the like. Alternatively, the LDEs46 can be connected to the inner (wearer-facing) surface of the coreassembly 23, or to any of the individual components of the core assembly23. In some embodiments, the LDEs 46 may extend laterally outward fromthe core assembly 23 and toward the corresponding end edge 56 andterminate at opposing ends that are joined to the inner (i.e.,body-facing) surface of the CAM 44 at the connection zones 48 (see FIG.1C). In some embodiments, the LDEs 46 may be joined to the outer-facingsurface of the CAM 44. The LDEs 46 may be joined to the CAM 44 and tothe core assembly 23 by any suitable means known in the art. Somesuitable examples include adhesive, cohesive, or the like.

Additionally, in some embodiments, the LDEs 46 can either be attacheddiscretely to the outer cover 24 or may be integral with the outer cover24. For example, as shown, in some embodiments, the LDEs 46 may bejoined to the CAM 44 at one end and to the core assembly 23 at theother, with the region in between being unbonded and free to stretch.Alternately, the LDEs 46 may have a relatively high force/moduluselastic that is either fully attached to or embedded in the outer cover24. An example of a suitable approach to achieving the latter can be toprint an elastomeric composition on the outer cover 24 via standardelastomeric printing techniques like gravure, offset gravure,flexographic, letterpress, screen, and inkjet printing, and via otherelastomer deposition techniques like spraying and slot coating. Anotherexample of a suitable approach can be to print thermoplasticnon-stretchable materials on the outer cover 24 via standardthermoplastic printing techniques. The formation of CAMs, LDEs and/oranchoring bands integral with the outer cover 24 is discussed hereafter.Alternatively to attaching the LDEs to the CAM, the LDE(s) and theCAM(s) can also be made as a unitary structure, e.g. be made from thesame material. Likewise, part of the core (e.g. the NWDL or the BLC) canbe unitary with the LDE(s) and/or the CAM.

Referring to FIGS. 2A-2C, during use, when the core assembly 23 absorbsan excremental load, this incremental load gives rise to additionalgravitational as well as inertial forces. For example, a gravitationalload force is applied to the core assembly 23 which tends to push theabsorbent assembly 23 downward. The absorbent assembly 23 transmits thegravitational load force to the LDEs 46 which in turn distribute theload force to the CAM 44A. The CAM 44A in turn, transfers thegravitational load force to the wearer's body (e.g., at the lower torsoregion). Part of the weight of the core assembly 23 (one quarter if thecore and urine loading are symmetrical with respect to the longitudinalcenterline and lateral centerline) can be transmitted through each LDE46 to the CAM 44A.

For any given urine load, the tension in the LDEs 46 increases as theangle of the LDEs 46 with respect to the longitudinal centerline 100(see beta shown in FIG. 1A,). Hence, the larger the angle that a givenLDE 46 makes with respect to the vertical when the diaper 20 is donnedon the wearer, the higher the tensile force that the LDE 46 will applyto the CAM 44A. If the CAM 44A stretches substantially under thistensile load, particularly between a connection zone 48 in the firstwaist region 36 and an adjacent connection zone 48 in the second waistregion 38, the circumference of the CAM 44A may increase thereby causingthe CAM 44A to lose some tension. Loss of tension by the CAM 44A maycause the CAM 44A to move down until the CAM 44A finds a new equilibriumlocation on the wearer's body. Accordingly, in certain aspects of thepresent invention, the portion of the CAM 44A between a connection zone48 in the first waist region 36 and an adjacent connection zone 48 inthe second waist region 38 may be elastic, extensile, ornon-stretchable. In some embodiments, the portion of the CAM 44A betweenadjacent connection zones 48, i.e. connection zone in the first waistregion and a connection zone in the second waist region, can beelongated by less than about 50 mm. In other embodiments, the connectionzones 48 may have the same stretch properties as the rest of thestretchable portions of the CAM 44A.

The LDEs 46, in some embodiments, can be joined to the CAM 44A such thatan angle beta (shown in FIG. 1A) defined between a given LDE 46 and thelongitudinal centerline 100, can be between about 10 and 80 degrees orany individual number within the range. It should be appreciated, as isdescribed in more detail below, that numerous alternatives to theembodiment illustrated in FIGS. 1A-1C are contemplated.

Because the generally downward forces applied to the core assembly 23during use are transferred to the CAM 44A via the LDEs 46, the coreassembly 23 can, in various embodiments, be supported without anyadditional core-supporting structure. Further, the performance of theanchoring system 42 can be enhanced if all other potential pathwaysbetween the core assembly 23 and all parts of the anchoring system 42and the chassis are force-decoupled. With this arrangement forcesgenerated at the core 26 may follow a pathway provided by the anchoringsystem 42 that bypasses the outer cover 24 at the crotch region 37 andat a portion of the front and back waist regions 36 and 38.

As will be described in more detail below, the anchoring system 42 maydefine a geodesic network when the diaper 20 is worn by the wearer inaccordance with certain aspects of the invention. It should beappreciated that the LDEs 46 can be arranged in any desired manner suchthat they provide for the transmission of the weight (gravitational andinertial forces) of the core assembly 23 and any of its contents (e.g.the elastic forces of the BLC being part of the core assembly) to theanchoring system 42 thus permitting the outer cover 24 to be renderedbiaxially stretchable or uniaxially stretchable without risk ofsubstantial sagging and/or distension due to the loads received by thecore 26 during use, especially if the core assembly is not stretchableor only stretchable to a lesser degree than the outer cover 24 Thebiaxial stretchability allows the outer cover 24 to conform to thewearer's body in an underwear-like manner.

In embodiments comprising the stretchable outer cover 24, the outercover 24 can force-decouple a potential pathway between the coreassembly 23 and the anchoring system 42 ensuring that the anchoringsystem 42 receives loads from the core assembly 23 only by the LDEs 46as opposed to receiving loads from the core assembly 23 by both the LDEs46 and the outer cover 24. In some embodiments, substantially all of theload from the core assembly 23 may be transferred to the CAM 44A via theLDEs 46. In order to achieve the force decoupling it may be desirable tominimize the coefficient of friction between (a) the outer cover and thecore, and (b) the outer cover and the CAM and LDE.

As shown in FIGS. 3A and 3B, in some embodiments, the anchoring system42 may comprise anchoring bands 44′ and 44″ which are connected directlyto the core assembly 23 without the use of LDEs. For example, theanchoring band 44′ can be connected to the core assembly 23 in the firstportion 1536 while the anchoring band 44″ can be connected to the coreassembly 23 in the second portion 1538. For embodiments comprising theanchoring system 42 of FIG. 3A, the assembled diaper 20 (shown in FIG.1A) includes a continuous CAM 44A (shown in FIGS. 2A-2C). Specifically,for the anchoring system 42 of FIG. 3A, the CAM 44A (shown in FIGS.2A-2C) is a closed loop and does not utilize a portion of the coreassembly 23 to close the loop about the waist of the wearer.

In contrast, embodiments comprising the anchoring system 42 of FIG. 3Binclude a discontinuous CAM 44A. Specifically, for the anchoring system42 of FIG. 3B, the CAM 44A is not a closed loop and utilizes a portionof the core assembly 23 as an anchoring system element to close the loopabout the waist of the wearer. As shown, in some embodiments, theanchoring band 44′ can be connected to the core assembly 23 in a firstlocation 402 and a second location 404. The first location 402 can belaterally spaced from the second location 404. As shown, the firstlocation 402 and the second location 404 can be disposed in the firstportion 1536 proximate to a first longitudinal edge 423A and a secondlongitudinal edge 423B of the core assembly 23.

In some embodiments, the anchoring band 44″ can be configured as shownin FIG. 3A or as shown in FIG. 3B. As shown in FIG. 3B, in someembodiments, the anchoring band 44″ can be connected to the coreassembly 23 at a third location 406 and a fourth location 408. The thirdlocation 406 can be laterally spaced from the fourth location 408.Similar to the first location 402 and the second location 404, the thirdlocation 406 and the fourth location 408 may be disposed in the secondportion 1538 proximate to the first longitudinal edge 423A and secondlongitudinal edge 423B.

As shown in FIGS. 4A through 4C, embodiments are contemplated whereinthe anchoring member 44′ is connected directly to the core assembly 23while the anchoring member 44″ is joined to the core assembly 23 viaLDEs 46 and vice versa. Connections directly to the core assembly 23include those discussed with regard to FIGS. 3A and 3B. Similarly,embodiments are contemplated where the anchoring band 44′ is configuredas described in FIG. 3A while the anchoring band 44″ is configured asdescribed in FIG. 3B, or vice versa.

Embodiments are contemplated where the anchoring system 42 comprisesmore than one CAM. For example, as shown in FIGS. 5A and 5B, theanchoring system 42 may comprise a first CAM 44A and a second CAM 44B.The first CAM 44A can be connected to first portion 1536 of the coreassembly 23 while the second CAM 44B is connected to the second portion1538 of the core assembly 23. As shown in FIG. 4A, in some embodiments,a CAM can be continuous. In contrast, as shown in FIG. 4B, in someembodiments, the core assembly 23 can form an implied anchoring band toclose the loop of a CAM. For the embodiment shown in FIG. 4B, a CAM canbe connected to the core assembly as described with regard to FIG. 3Band the first location 402, second location 404, third location 406, andthe fourth location 408. In some embodiments, the anchoring system maybe configured as described with regard to FIG. 5A. However, instead ofbeing connected to the core assembly 23, a CAM can be joined to the coreassembly 23 via a plurality of LDEs.

With regard to FIGS. 5A and 5B, in some embodiments, the first CAM 44Acan be joined to the second CAM 44B proximal to a point of intersectionbetween the first CAM 44A and the second CAM 44B. By joining the firstCAM 44A and the second CAM 44B to one another, each of the CAMs canprovide lateral stabilization to the other CAM. The lateralstabilization can reduce the likelihood that the first CAM 44A and/orthe second CAM 44B will move relative to the wearer during dynamicmovement.

While the LDEs 46 may be directly connected to the CAM 44 as describedabove with reference to FIG. 1A, it should be appreciated that thepresent invention alternatively contemplates the CAM 44 connected to theLDEs 46 via an intermediate load element 1543 which may act as aconnection zone 48, as illustrated in FIG. 6. As shown in FIG. 6, insome embodiments, the LDEs 46 may comprise elongated bands that areattached at one end to the core assembly 23 on either side of thelongitudinal centerline 100 (and proximal thereto), and are connected attheir other ends to the intermediate load element 1543. In turn, theintermediate load element 1543 may act as the connection zone 48 whichjoins the LDEs 46 to the corresponding anchoring band 44′ or 44″. Theproperties of the intermediate load element 1543 can be similar to theproperties of the CAM 44, anchoring bands 44′ and 44″, and LDEs 46,discussed hereafter.

Other embodiments of the present invention include a stabilization band.For example, as shown in FIGS. 7A and 7B, the anchoring system 42 maycomprise a stabilization band 710 which is joined to the first CAM 44A.As shown, in FIG. 7A, the stabilization band 710 may be discontinuous.Specifically, as shown, the stabilization band 710 may not be a closedloop independently from the first CAM 44A. Alternatively, in someembodiments, as shown in FIG. 7B, the stabilization band 710 may becontinuous, i.e. a closed loop independently from the first CAM 44.

Regardless of whether the stabilization band 710 is continuous ordiscontinuous, the stabilization band can be joined to the first CAM 44Athereby providing lateral support to the first CAM 44A. For example, thestabilization band 710 can reduce the likelihood that a portion of thefirst CAM 44A will slide down the hip of the wearer during dynamicmovement. In various embodiments, a stabilization band can benon-stretch or elastic.

Additionally, the first CAM 44A can be joined to the core assembly 23 asdiscussed heretofore. For example, the first CAM 44A may be directlyconnected to the core assembly 23 in the front portion 1536 (shown inFIG. 1A) and directly connected to the core assembly 23 in the backportion 1538 (shown in FIG. 1A). As another example, the first CAM 44Acan be joined to core assembly 23 in the front portion 1536 (shown inFIG. 1A) and/or the second portion 1538 (shown in FIG. 1A) via LDEs 46(shown in FIG. 1A). As yet another example, the first CAM 44A can bedirectly connected to the core assembly 23 in the front portion 1536(shown in FIG. 1A) and/or the back portion 1538 (shown in FIG. 1A) asdescribed heretofore with regard to FIGS. 3A and 3B, 4A and 4C, and 5Aand 5B.

The CAMs of the present invention can be made from any suitable materialknown in the art. For example, the CAM can be an elastomeric material inany form, e.g. extruded film, elastic non-woven, scrim, slot-coatedfilm, sprayed or meltblown fibers, printed elastics, or any othersuitable process known in the art for manufacturing elastomericmaterial. In embodiments comprising an outer cover (as describedheretofore with regard to FIG. 1A), the CAM may be attached to the outercover either on line during the diaper manufacturing process, or it maybe incorporated into the outer cover during the outer covermanufacturing process. An example of the latter is elastomer printing,wherein, in a specific embodiment, the print pattern on the printingroll is such that the higher caliper region forms the higher-force CAM,while the lower caliper region forms the rest of the outer cover.Anchoring systems formed as a portion of the outer cover are discussedhereafter.

In some embodiments, the CAM may have a first cycle force greater thanabout 50 grams at about 15% strain. In some embodiments, the CAM mayhave a first cycle force of between about 75 grams and about 1000 gramsor any individual number within the range. In some embodiments, the CAMmay have a first cycle load of between about 100 grams and about 500grams. In some embodiments, the CAM may have a first cycle load ofbetween about 150 grams and about 300 grams. It should be noted thatthis force is measured at the actual width of the CAM.

The CAM may be of any suitable width known in the art. For example, insome embodiments, the CAM may vary in width from about 5 mm to about 75mm or any individual number within the range. In some embodiments, theCAM may vary in width from about 10 mm to about 50 mm. In someembodiments, the CAM may vary in width from about 15 mm to about 35 mm.

It should be appreciated that the CAM can have a variable width and/orthickness along its length, either of which would produce discreteregions on the CAM having different stretch properties (e.g., thatstretch to different extents). The variable width and/or thickness couldbe achieved, for example, using an elastomeric printing processappreciated by one having ordinary skill in the art.

The CAM has higher modulus (slope of the stress-strain curve) than themodulus of the outer cover to prevent excessive sagging with eachincrement of load. The CAM, in some embodiments, can have certainportions that are elastic and other portions that are either extensibleor non-stretchable (i.e. elastic over one or more portions of its lengthand inelastic or non-stretchable over the remaining portions). Forexample, a section of the CAM that is connected to a non-stretchablecore assembly need not be stretchable, since this core assembly wouldprevent the CAM from stretching.

The CAM stretches predominantly in the lateral direction. A key part ofthe invention is that CAM has a higher tensile force compared to theremainder of the outer cover. At 15% strain (first cycle), the ratio oflateral CAM force per unit width to the remainder of the outer cover ortopsheet force per unit width is greater than 1.5, more preferablygreater than 2, even more preferably greater than 5, and most preferablygreater than 10.

In embodiments where the diaper is a pant, the CAM can be elastic inorder to allow the diaper to stretch in the lateral direction duringapplication, given that the initial diaper circumference can be preset.This desirability can be increased when a single size diaper is intendedto fit a range of wearers in a given size. In embodiments where thediaper is a taped diaper, the size adjustability can be at leastpartially achieved by the fastener placement on a landing zone or otherfastener receiving surface and, as a result, while the CAM can beelastic, a non-stretchable, or extensible, CAM is similarly feasible.

The LDEs 46, in some embodiments, may be non-stretchable so as totransfer the load forces at the core 26 to the connection zone 48 of theCAM 44. The LDEs of the present invention may comprise, in someembodiments an elastic material, an extensible material, and/or anon-stretchable material. The LDEs 46 may be formed utilizing anysuitable material known in the art. For example, the LDEs 46 can beformed from nonwovens, films, elastomeric structures, and the like.

It should be appreciated that the LDEs 46 can alternatively beextensible or stretchable, in which case they preferably have a lowstrain force limit. For example, the LDEs 46 may be able to stretch tosome low level of strain, e.g. 50%. Beyond the strain of 50%, forexample, the slope of the stress strain curve can increase compared tothe slope of the stress strain curve from 0% to 50% strain. Suchmaterials may be beneficial in reducing wet core drooping due to wearermovements like walking and running. The low strain force limit can beachieved, for example, with stretch bonding, whereby an elastomericfilm, filaments or nonwoven is stretched in the machine direction,bonded to a substrate web, such as a nonwoven, and allowed to retractand gather; or, as another example, via incremental stretching to arelatively small level of strain. For example, a nonwoven that comprisesa mix of elastomeric and non-elastomeric fibers/filaments is notelastic. However, upon incremental stretching, the web may becomeelastic.

In general, incremental stretching can be used to release the stretchproperties of a composite that comprises elastic and inelasticcomponents, e.g. an elastic web laminated to an inelastic web. Inaccordance with certain aspects of the present invention, the low levelof strain can be less than about 50%, alternatively less than about 40%,alternatively still less than about 30%, alternatively still less thanabout 25%, and alternatively still less than about 20% for a linkagethat is between about 50 and about 150 mm long or any individual numberwithin the range. The extensibility/stretchability of the LDEs permitsthe diaper 20 to expand in the longitudinal and lateral directions,thereby providing a conforming fit for a wider range of wearers that isimproved with respect to conventional absorbent articles. Furthermore,extensible or elastic LDEs 46 can accommodate wearer movement duringuse, and further accommodate core swelling as loads are deposited in thecore 26.

In some embodiments, the load of the LDE at 15% strain (first cycle) inthe Hysteresis test is at least about 40 gm, preferably more than about75 gm and most preferably greater than about 100 gm. In someembodiments, the LDEs 46 can have a width ranging from about 5 mm toabout 50 mm. It should be noted that the sample width in the Hysteresistest should be the same as the width of the LDE. Also, the lengthdirection of the LDE is the direction in which it is pulled in use. Insome embodiments, the LDEs 46 and/or the CAM 44 may alternativelycomprise a multiplicity of subcomponents, such as strands or filaments,having individual widths of less than 5 mm. In accordance with certainaspects of the present invention, in some embodiments, the LDEs 46 areless extensible (e.g., have a higher elastic modulus) than the outercover 24 to reduce the ability for wearer movement to cause the coreassembly 23 to bias the outer cover 24, e.g. cause the waist and/or legperimeters to move with respect to the wearer.

The integral formation of anchoring bands, CAMs, and/or LDEs as part ofthe outer cover is contemplated in some embodiments. For example, asshown in FIG. 8, in some embodiments, the LDEs 46 and/or the CAM 44 maybe integrally formed in the outer cover 24 by differential incrementalstretching of the outer cover 24. The core assembly has been omitted inFIG. 8 to show details of the integral anchoring system. As shown, insome embodiments, portions of the outer cover 24 that correspond to theLDEs 46, the anchoring band 44′ and/or the anchoring band 44″, areeither not incrementally stretched or are stretched to a lesser extentcompared to the rest of the outer cover 24. In some embodiments, a firstportion of the CAM may be a discrete band or other separate element thatis attached to the chassis 21, while a second portion of circumferentialanchoring member is integral with the outer cover 24 to which thediscrete band or other separate element is attached.

As shown in FIG. 8, in some embodiments, the outer cover 24 may bejoined to the LDEs 46 at their respective connection zones 48.Additionally, in some embodiments, the LDEs 46 may be integral with theanchoring bands 44′ and/or 44″. For example, in some embodiments, theLDEs 46, the anchoring band 44′, and the anchoring bands 44″, maycomprise a contiguous portion of underactivated or nonactivated area. Asshown, in some embodiments, where the LDEs 46 are integral with theouter cover 24, the outer cover 24 can be joined to the core assembly 23at the connection zones 48.

In accordance with one aspect of the present invention, if the LDEs 46are formed from the outer cover 24, the LDEs 46 can be renderedextensible, non-stretchable, or elastic, such that the forces exerted onthe core 26 are transferred to the CAM 44 while preventing the core 26from substantially sagging. In embodiments, where the LDEs 46 and/or theCAM 44 are integral with the outer cover, the LDEs 46 and CAM 44 shouldhave a higher modulus of elasticity than the modulus of elasticity ofother portions of the outer cover 24 which do not comprise the LDEs 46and/or the CAM 44.

The anchoring system of the present invention may have a higher moduluscompared to the rest of the outer cover. This higher modulus can beachieved by using a higher caliper and/or higher performance elastomer,via differential incremental stretching, or over-bonding. Differentialincremental stretching refers to incremental stretching of differentregions of a substrate to different strain levels as describedheretofore.

As described above, the circumferential anchoring member and/or LDEs caneither be integral with the biaxially stretchable outer cover or bediscretely attached to the biaxially stretchable outer cover. In someembodiments, an integral anchoring system may be created by differentialincremental stretching of a biaxially stretchable outer cover precursor.The term “biaxially stretchable outer cover precursor” refers to abiaxially stretchable outer cover prior to incremental stretching. Theterm “biaxially stretchable” as used herein refers to the ability tostretch along two orthogonal axes that extend coplanar with the outercover. The regions on the biaxially stretchable outer cover thatcorrespond to the anchoring system either are not incrementallystretched or are stretched to a lesser extent compared to the rest ofthe biaxially stretchable outer cover.

In some embodiments, an integral anchoring system includes printing ofan elastomeric composition in the areas where the circumferentialanchoring member and/or LDEs are located on the biaxially stretchableouter cover precursor, followed by differential incremental stretchingwherein the anchoring system components (i.e., LDEs and/orcircumferential anchoring member) can be stretched to a lesser extentcompared to the rest of the biaxially stretchable outer cover. Theprinting of the biaxially stretchable outer cover elastomer and theanchoring system elastomer onto the nonwoven substrate can be done inone step if they are the same chemistry, or in multiple steps if theyare different chemistries. In some embodiments, non-stretch polymers canbe printed and/or deposited to make integral anchoring system elementswith non-stretch portions.

In some embodiments, the circumferential anchoring member and/or LDEscan also be attached to the biaxially stretchable outer coverdiscretely. An example is an on-line cut and slip process in which theseelements are cut from an elastomeric film or a film-nonwoven laminateand attached to the biaxially stretchable outer cover.

In accordance with the methods described herein, an elastomer may becombined with a nonwoven web. The elastomer can be in the form of afilm, a nonwoven, a crosshatch pattern, stripes in the lateral and/orlongitudinal directions, stripes in any direction, or any other shape,and is laminated to a nonwoven.

In some embodiments, the elastomer may be printed onto the nonwoven webas described heretofore. The main advantage of printing is that it hasthe capability of delivering a very small amount of elastomer on thenonwoven, thus producing a low force member. For example, a pattern thathas 1 mm wide stripes that are 4 mm apart will have about one fifth theforce of a solid film. Another advantage of printing is that a smallquantity of a high performance elastomer can be used to deliver thedesired force and recovery properties, thus keeping manufacturing costsdown. Regardless of the method by which the elastomer and nonwoven webare combined, the resultant web may be subjected to selectiveincremental stretching in the areas of the web which are intended toextend or stretch in use, i.e., during wearer movements. Any areas ofthe web intended to form a portion of the anchoring system (i.e., theCAM or LDEs) may be incrementally stretched to a lesser degree than thesurrounding portions of the web. The above described can be applied toan absorbent article 120 of the embodiment of FIG. 13A and to theabsorbent article 20 discussed heretofore.

The incorporation of anchoring systems into the articles of the presentinvention enables the articles to fit higher on the body initially(i.e., they do not “snap back” as much once application tension isreleased), fit a broader range of wearer “rises” (i.e., especially whenbiaxial outer cover stretch is employed such that the product can adjustin the longitudinal direction) and have a better sustained fit. It hasbeen found that these effects enable the reduction in theas-manufactured longitudinal dimension (or “pitch”) of the articles ofthe present invention. This provides these articles a moreunderwear-like appearance in their bi-folded state (i.e., when folded attheir lateral centerline only) since they have an aspect ratio (foldedheight to width) similar to underwear. The articles of the presentinvention may have an aspect ratio of from between about 1.2 and about0.7.

Outer Cover

As discussed previously, the outer cover may be stretchable in one ormore directions, elastic in one or more directions, or non-stretchable.The side edges 54 of the outer cover 24 create perimeters about the legsof a wearer, and similarly, the end edges 56 of the outer cover 24create a waist perimeter about the wearer. These perimeters can moverelative to the anchoring system 42, thereby changing the distancesbetween the perimeters and the anchoring system 42. For example, from aneutral standing position, these distances increase particularly in theback region when the knees are raised or the wearer bends forward at thewaist.

In some embodiments, the waist and/or leg perimeters can beforce-decoupled from the anchoring system 42 by a bi-axially stretchableouter cover 24, or “BSOC”, that is designed to minimize forces thatarise between the waist or leg perimeters and the anchoring system 42from movement of the legs and spine relative to the pelvis. In contrast,if the outer cover 24 were non-stretchable, such movements may encumberthe wearer, or such movements may cause the perimeters to move relativeto the waist and leg regions of the wearer. It will be thus appreciatedthat the anchoring system 42 and BSOC enables the diaper 20 to achievean enhanced, more comfortable and underwear-like fit relative toconventional diapers. Embodiments are contemplated where the outer cover24 is stretchable along one direction (e.g. the lateral, the transversedirection, or any other direction). In these embodiments, the waistand/or leg perimeters can similarly be force-decoupled from theanchoring system 42.

The outer cover, in some embodiments, can be impervious to liquids(e.g., urine) and manufactured from a thin plastic film or a nonwovenweb, although other flexible liquid impervious materials which arecompliant and will readily conform to the general shape and contours ofthe human body can also be used. Additionally, in some embodiments, theouter cover 24 may comprise a laminated structure.

The outer cover may be generally positioned such that it can be at leasta portion of the garment-facing surface of the diaper. The outer covercan prevent the exudates absorbed and contained within the diaper fromsoiling articles that can contact the diaper, such as bed sheets andundergarments, in some embodiments. Suitable outer cover materialsinclude films such as those manufactured by Tredegar Industries Inc. ofTerre Haute, Ind. and sold under the trade names X15306, X10962, andX10964. In various embodiments, the outer cover can include an inelasticnonwoven. The outer cover can be a thermoplastic film having a thicknessof from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils). Anotherexample of a suitable film which can be utilized in the outer cover 24includes a 0.5-1.0 mil (0.0005-0.001″) thick Vistamaxx (elastomericpolypropylene from ExxonMobil). In some embodiments, elastomericpolypropylene based compositions are disclosed in WO 2005/052052 toExxonMobil and in WO 2005/097031 to Procter & Gamble. The elastomericcomposition may also include fillers like titanium dioxide for improvingopacity and calcium carbonate for breathability. The elastomericpolypropylenes may also be blended with styrenic block copolymers,semicrystalline polyolefins or sub-micron inorganic particles.

In some embodiments, the outer cover 24 may comprise an elasticnonwoven. In some embodiments, the outer cover 24 may comprise alaminate including an elastic nonwoven and a plastic film, for example,polyethylene film. In some embodiments, the outer cover 24 may comprisea laminate including an elastic film and a non-elastic nonwoven. In someembodiments, the outer cover 24 may comprise a laminate includingprinted elastics. In some embodiments, the outer cover 24 may comprise alaminate including an elastic in the form of a scrim-like structure or acrosshatch pattern that is joined between two layers of a nonwoven orbetween a nonwoven and a breathable film (e.g. polyethylene film), etc.

The elastomeric film examples provided above can be laminated to atleast one layer of non-elastomeric or extensible nonwoven using spiralglue. Additionally, this laminate can be incrementally stretched in amachine direction and then in a cross machine direction thereby forminga biaxially stretchable elastic laminate. A suitable example of anonwoven which can be utilized in the outer cover 24 includes DAPP. Asuitable DAPP nonwoven is sold under the designation Softspan 200available from BBA Fiberweb, Brentwood Tenn. In some embodiments theDAPP can be joined to an elastic element, e.g. elastomeric scrim andjoined to a polyethylene film. In some embodiments, the DAPP can bejoined to an elastic element, e.g. elastomeric scrim and joined toanother DAPP nonwoven.

Outer cover laminates, such as those described above, wherein theelastomeric component is combined with another web in a relaxed,unstretched state, are referred to in the art as “zero-strainlaminates”. While in some embodiments, the zero-strain laminate may beinherently stretchable in a virgin state, the stretch properties ofthese materials are usually released or improved by mechanicalactivation, or incremental stretching, such as ring rolling or SELFing.Alternatively, pre-stretched laminate materials may also be employed asouter cover materials in the present invention. Pre-stretchedelastomeric outer covers are formed by applying an elastomeric material,e.g., strands or films, to a substrate while the elastomeric material isin a prestrained state, and subsequently allowing the laminate to relaxand contract. Pre-stretched biaxially stretchable outer cover materialsmay be formed by applying pre-tensioned elastomeric elements in at leasttwo different directions, preferably, but not necessarily, aligned withthe longitudinal and lateral axes of the article. In certainembodiments, outer covers of the present invention may include bothzero-strain and pre-stretched elastomers. For example, a pre-tensionedelastomeric element may be affixed to a zero-strain elastomeric laminateeither parallel to the zero strain laminate's primary direction ofstretch or at an angle thereto.

In some embodiments, the outer cover 24 may comprise an elastomericlayer which includes an elastomeric adhesive, e.g. a hot melt pressuresensitive adhesive. In these embodiments, additional adhesive may not beneeded to bond the layers of the laminate together. However, if theelastomeric material does not have good adhesive properties, additionaladhesive may be utilized.

In some embodiments, the outer cover 24 may have a low force at aspecific elongation as measured by the Hysteresis Test (50% MaximumStrain). Since the outer cover can have different stretch properties indifferent directions, stretch properties in the Hysteresis Test aremeasured in the longitudinal direction (machine direction), lateraldirection (cross machine direction) and in a direction that is parallelto the length direction of the anchoring band. In some embodiments, theouter cover 24 may have a first cycle force less than about 20 gm/cm at15% strain. In some embodiments, the outer cover 24 may have a firstcycle force less than about 15 gm/cm at 15% strain. In some embodiments,the outer cover 24 may have a first cycle force less than about 10 gm/cmat 15% strain.

Additionally, in some embodiments, the outer cover 24 may also have apercentage set (as measured by the Hysteresis Test) which is less thanabout 40% after about a 50% load Hysteresis Test. In some embodiments,the outer cover 24 may have a percentage set which is less than about30% or in some embodiments, less than about 15%.

In some embodiments, the outer cover 24 may be sufficiently breathable.For example, in some embodiments, the outer cover 24 can be constructedto be permeable to at least water vapor and can have a moisture vaportransmission rate (MVTR) of at least 1000 g/m²/24 hr., preferably atleast 1500 g/m²/24 hr., more preferably at least 2000 g/m²/24 hr., andeven more preferably at least 3000 g/m²/24 hr. In other embodiments, theouter cover has an MVTR of at least about 7000 g/m²/24 hr. In someembodiments, the outer cover 24 may have a moisture vapor transmissionrate of from about 1000 to about 8000 g/m²/24 hr. or any individualnumber within the range. Some breathable backsheet materials aredescribed in greater detail in PCT Application No. WO 95/16746; U.S.Pat. No. 5,938,648; U.S. Pat. No. 5,865,823; and U.S. Pat. No.5,571,096. Other suitable exemplary materials and a suitable test methodfor measuring the MVTR is described in U.S. Pat. No. 6,448,467.Additionally, in some embodiments, the outer cover 24 may compriseunderwear-like texture/aesthetics. One aspect of underwear likeaesthetics is gloss (as measured according to ASTM D2457-97) to give apleasing mate look (not plastic like). A gloss value of 7 gloss units orless has been found desirable. Embossing and/or matte finishing improvesthe outer covers gloss.

The outer cover 24, in some embodiments, may have sufficient opacitysuch that exudates discharged into a core assembly 23 cannot be readilyperceived from a vantage point external to the diaper 20. Also, theouter cover may have sufficient opacity to prevent the skin from beingseen in the non-core areas of the diaper. In order to increase theopacity of biaxially stretchable outer cover elastic nonwovens, in someembodiments, at least one meltblown may be incorporated into thespunbond web. The meltblown layer may consist of nano-fibers. Themeltblown layer may have a basis weight of between about 1 gsm and about20 gsm or any individual number within the range. In some embodimentsthe meltblown layer may have a basis weight of between about 4 gsm andabout 15 gsm and may comprise various combinations of elastomeric andplastic polymeric resins. Higher elastomeric content may be preferredwhen higher depths of activation (incremental stretching) are requiredand/or when lower permanent set values in the outer cover are desired.Elastomeric and plastic polyolefin combinations may utilized in someembodiments to optimize the cost/performance balance. In someembodiments, the elastomeric component may comprise a very lowcrystallinity polypropylene grade such as those commercialized byExxonMobil under the tradename Vistamaxx. Additionally, the elasticnonwoven structure may also include another spunbond layer that does notprovide significant elastic recovery, yet possesses sufficientextensibility to survive the activation process. Some suitable examplesof such extensible spunbond nonwoven layers are disclosed in WO2005/073308 and WO 2005/073309.

Other exemplary breathable materials can include materials such as wovenwebs, nonwoven webs, polymeric films such as thermoplastic films ofpolyethylene or polypropylene, composite materials such as film-coatednonwoven webs, and microporous films such as manufactured by MitsuiToatsu Co., of Japan under the designation ESPOIR NO and by EXXONChemical Co., of Bay City, Tex., under the designation EXXAIRE. Suitablebreathable composite materials comprising polymer blends are availablefrom Clopay Corporation, Cincinnati, Ohio under the name HYTREL blendP18-3097. An exemplary, suitable outer cover is disclosed in U.S. Pat.No. 6,107,537.

All or a portion of the outer cover can be ring-rolled and thus renderedhighly extensible as described in U.S. Pat. No. 5,366,782 (issued Nov.22, 1994 to Curro, et al). Specifically, a ring-rolling apparatusincludes opposing rolls having intermeshing teeth that incrementallystretch and thereby plastically deform the material forming outer cover(or a portion thereof) thereby rendering the outer cover extensible inthe ring-rolled regions. In some embodiments, the outer cover can bering-rolled in a portion of at least one of the front or back waistregions while other regions may comprise a structured elastic-likeformed web material or virgin or unactivated regions. Similarly, thechassis can be ring-rolled across the entire width in one or both of thewaist regions or alternatively can be ring-rolled over only a portion ofthe chassis width. Ring rolling can be performed in one or multipledirections. For example, to make a biaxial stretchable outer cover, thenonwoven-elastic laminate can be first activated in, say, the lateraldirection, and then in the longitudinal direction. Alternatively, thenonwoven-elastic laminate may be activated in any two directions alignedwith, or at angles to, the longitudinal and/or lateral axes of thearticle. For example, the laminate may be activated plus and minus 45degrees from the longitudinal axis. Alternatively, the laminate may beactivated at plus 60 and minus 30 degrees from the longitudinal axis.

Alternatively, the outer cover can comprise a structural elastic-likefilm (SELF) web that is stretchable along one or more of thelongitudinal and lateral axes 200 and 210 (in FIG. 13A). SELF webssuitable for the present invention are more completely described in thecommonly assigned U.S. Pat. No. 5,518,801 entitled “Web MaterialsExhibiting Elastic-Like Behavior” issued to Chappell et al. on May 21,1996.

Other suitable materials and/or manufacturing techniques can be used toprovide a suitable outer cover including, but not limited to, surfacetreatments, particular film selections and processing, particularfilament selections and processing, etc. The outer cover can be embossedand/or matte finished to provide a more clothlike appearance.

As described above, the biaxial stretchable outer cover, in someembodiments, has a low force, recoverable stretch (for instance, lessthan about 15 g/cm at a strain of 50%), similar to a cotton underwear.Such an outer cover can be made in several ways (e.g. via elastomericnonwovens, printed elastics, spraying, and lamination). Nonwovens thatpredominantly have elastomeric fibers or filaments have a rubbery feeland are generally not desired by consumers. Since the stretchability ofthe outer cover occurs at low forces, it is possible to use a blend ofelastomeric, e.g., very low crystallinity elastomeric polypropylene, andplastic, e.g., polypropylene, filaments. Exemplary structures arediscussed in WO 2005/065680; WO 2005/052052; and WO 2005/097031.Advantages to using such a blend include the fact that the thermoplasticfibers help improve the feel of the outer cover 124 to the wearer/user.Additionally such a blend provides a force limit, as the nonwoven isincrementally stretched in order to release the stretch properties. Analternative method for fabricating the biaxially stretchable outer coveris to provide an elastomeric nonwoven structure that comprisesbicomponent fibers having an elastomeric core and a thermoplasticsheath. Exemplary structures are discussed in U.S. Pat. No. 6,225,243;U.S. Pat. No. 5,470,639; and U.S. Pat. No. 5,997,989. This nonwoven mayalso have improved feel.

In both the above methods, the elastomeric nonwoven can be incrementallystretched to release the stretch. The nonwoven biaxial stretchable outercover can be carded, spunbond, SMS (sponbond-meltblown-spunbond), orotherwise fabricated. The fine fibers of the meltblown layer in the SMSstructure provide enhanced opacity, a desirable feature in outer covers.Replacing the meltblown layer with nano fibers may further increase theopacity of the outer cover.

The biaxially stretchable outer cover can also be made by elastomerprinting, spraying, slot coating, meltblown or film lamination. Printingincludes gravure, flexographic, letterpress, screen, digital, or thelike. Some suitable examples of printing are described in U.S.Application Publication No. 2003/0088220A1; U.S. Application PublicationNo. US 2003/0088228A1; U.S. Application Publication No. 2003/0091807A1;U.S. Application Publication No. 2004/0193133A1; U.S. ApplicationPublication No. 2004/0222553A1; U.S. Application Publication No.2005/0214461A1; U.S. Application Publication No. 2003/0084996A1; U.S.Application Publication No. 2003/0084996A1; U.S. Application PublicationNo. 2003/0087059A1; U.S. Application Publication No. 2003/0087098A1;U.S. Pat. No. 6,875,710; and U.S. Pat. No. 6,942,894.

Spraying includes standard techniques for hot melt adhesive spraying,e.g. spiral, zig-zag pattern, ITW/s Omega pattern, meltblown, etc. Anelastomeric film can be bonded to a nonwoven by extrusion or adhesivelamination. Preferably, the elastomeric film is breathable.

In accordance with certain aspects of the invention, various materialscan be used to provide a biaxially stretchable outer cover in accordancewith various embodiments of the present invention. When constructing thebiaxially stretchable outer cover, various desirable features includethe following:

-   -   Mechanical properties (as expressed in terms as measured in a        Hysteresis test) during multiple medium-strain stretch-recovery        cycles; As well as the ability to survive high-strain-rate        medium depth of engagement Mechanical Activation in both machine        direction and cross direction without pinhole);    -   Durability (low Fuzz, high Ultimate Strength);    -   Visuals (white color, high opacity, cotton-ribbon-like texture,        printable, gloss);    -   Liquid Barrier properties in some embodiments (absence of        pinholes or any other signs that could signal the possibility of        outer cover leakage); and    -   Low cost.

Variations in specific targets may be found depending upon whether thedesign is for a pant or a taped diaper. For instance, as is described inmore detail below, one embodiment of a taped diaper design has anintegrated anchoring system built into the biaxially stretchable outercover which is created by differential activation (an area of thebiaxially stretchable outer cover is intentionally left un-activated).Therefore, the development of the outer cover material takes intoaccount performance targets for both pre- and post-activation states.The pant design may have more stringent upper limits for the CD stretchload of the biaxially stretchable outer cover in order to maintain easydiaper application.

The biaxially stretchable outer cover preferably has mechanical and/orelastic properties as described herein, as well as the ability tosurvive high-strain-rate mechanical activation (i.e., incrementalstretching) in both the longitudinal and lateral directions withoutpinhole formation. Laminates which exhibit reduced pinholes fromactivation are described in U.S. application Ser. No. 11/361,918,entitled, “Method of Making Laminate Structures for MechanicalActivation”, filed on Feb. 24, 2006, on behalf of Anderson et al.Additionally, the outer covers of the present invention preferably havea low tendency to fuzz, have high opacity, and are printable viaprinting processes common to the art.

The biaxially stretchable outer cover may be formed from any elastic orextensible web material or composite as known in the art. The biaxiallystretchable outer cover may comprise an elastic nonwoven, an elasticnonwoven laminated with an extensible and/or elastic film or scrim, anextensible nonwoven laminated with an elastic film or scrim, a webcomprising an elastomer pattern printed on an elastic and/or extensiblenonwoven, variants of any of the preceding materials at least a portionof which is mechanically pre-strained, or any other elastic orextensible materials as known in the art.

In some embodiments of the present invention, the biaxially stretchableouter cover comprises only an elastic nonwoven. In these embodiments thetotal basis weight of the outer cover may be less than about 50 gsm,preferably less than about 40 gsm, and more preferably less than about35 gsm. The outer cover material may comprise a spunbond fabric and beproduced under conditions that promote optimal bond strength in order toprovide sufficient strength and durability to the outer cover. Elasticnonwoven outer covers include at least one elastomeric material in asufficient amount to provide a minimal desirable amount of recovery.Examples of suitable spunbond nonwovens are described in U.S. Pat. Nos.5,470,639 and 5,997,989. In some embodiments of the present invention,the elastic nonwoven comprises elastic/plastic bicomponent fibers,examples of which are described in U.S. Pat. No. 6,225,243 andWO2006/017674, to provide the outer cover material with better hand/feelproperties and improved spinnability. The outer cover material may alsocomprise webs, i.e., as disclosed in WO 2005/065680, formed of mixedelastic fibers (e.g., thermoplastic polyurethane elastomer) and plastic(e.g., polyolefins such as polypropylene) fibers, said nonwovens havinggood elastic recovery and tactile properties after being subjected tomechanical activation, such as Vistamax™ available from Exxon Anothersuitable elastic component is very low crystallinity elastomericpolypropylene. Other suitable examples of spunbond elastic nonwovens aredisclosed in WO 2005/052052 and WO 2005/097031. In embodiments whereinthe elastic nonwoven outer cover comprises mixtures or composites ofboth elastic and plastic materials, the ratio of the elastic to plasticcomponents can be tailored to provide a desirable balance of bothstretch/recovery characteristics and strength/toughness requirements.High toughness is desirable to maximize the ability of the web tosurvive mechanical activation in both the longitudinal and lateraldirections.

Other exemplary materials suitable for the outer cover are disclosed inU.S. Pat. No. 6,896,843; U.S. Pat. No. 6,225,243; U.S. Pat. No.5,997,989; U.S. Pat. No. 5,952,252; U.S. Pat. No. 5,695,849; U.S. Pat.No. 5,470,639; U.S. Pat. No. 5,405,682; WO 2005/052052; WO 2004/065680;WO 2006/017674; US 2004/0132374; US 2004/0110442; US 2003/0162458; U.S.Pat. No. 6,811,871; U.S. Pat. No. 6,103,647; U.S. Pat. No. 5,635,290;and U.S. Pat. No. 5,540,976.

In some embodiments of the present invention, the biaxially stretchableouter cover may comprise a laminate of elastic nonwovens, such as thosedescribed in the preceding section, and an extensible film. In thisembodiment, a thin extensible polyolefin film layer is laminated ontothe elastic nonwoven described above. Although higher basis weights arecontemplated in certain embodiments, the basis weight of the film may beno more than about 22 gsm, preferably no more than about 20 gsm, andmore preferably no more than about 18 gsm in order to minimize the costof the laminate. The film may be combined with the elastomeric nonwovenvia adhesive lamination, extrusion lamination, or any other suitablemeans of combining webs as known in the art. The film may preferably beextensible in both longitudinal and lateral directions and able tosurvive a mechanical activation (i.e., incremental stretching) processwithout pinhole formation over the relevant range of activation strains.The film may preferably be breathable, as discussed previously, whetherthe breathability originates from activation-induced micro-porosity orvirtually invisible pinholes. The film may be either extensible, i.e.plastic, or it may be plastoelastic and exhibit partial recovery, henceparticipating in the elastic recovery process. Examples of “plastic”films include films comprising standard filled polyethylene resins, e.g.those disclosed in WO 2006/017518. Examples of the use of plastoelasticfilm formulations are disclosed in WO 2005/097031. The presence of thefilm laminated onto the stretch NW contributes to create highlydesirable visuals such as high opacity and high texture without the needfor incorporating the type of melt-blown layer described above.Alternatively, the film may comprise high-performance elastomers such asKraton-based elastomers. Further examples of elastic nonwoven/extensiblefilm laminates suitable for the present invention are disclosed in WO2005/017518; US 2005/0124952; U.S. Pat. No. 6,811,865; U.S. Pat. No.6,623,837; and U.S. Pat. No. 6,096,668.

In some embodiments, the film can be the component that exhibits atleast partial recovery upon stretching. The nonwoven may be anextensible spunbond or a necked/gathered spunbond of the types describedabove. As described above, in some embodiments, the basis weight of thefilm may be no more than about 22 gsm, preferably no more than aboutthan 20 gsm, more preferably no more than about 18 gsm in order tominimize the cost of the laminate as well as minimize the force requiredto stretch the BSOC up to 50% strain. The film may be combined with thenonwoven either via adhesive lamination or via extrusion lamination. Thefilm should be selected as described above such as to survive anincremental stretching process without pinhole formation over therelevant range of activation strains. The film may be breathable asdescribed herein. An example of a filled elastic polyethylene blend filmis disclosed in U.S. Pat. No. 6,909, 028. Preferred elastomericpolypropylene-based compositions are disclosed in WO 2005/052052 and inWO 2005/097031. Blends of elastomeric polypropylenes with eitherstyrenic block-copolymers, semicrystalline polyolefins or sub-microninorganic particles can be used to enhance the stress-strain andhysteresis properties of the laminate. For example, decreasing the forcerequired to extend the BSOC and improving elastic recovery is achievableby adding styrenic block copolymers into a Vistamaxx polymer.Micro-porous breathable elastic films based on calcium carbonate-filledelastomeric polypropylene-based compositions are also contemplated. Thefilm may additionally increase the opacity of the BSOC and potentiallyeliminate or reduce the need for the presence of a meltblown layer inthe nonwoven.

Exemplary BSOC materials related to these embodiments are disclosed inU.S. Pat. No. 6,909,028; U.S. Pat. No. 6,680,265; U.S. Pat. No.6,680,265; U.S. Pat. No. 6,015,764; U.S. Pat. No. 5,947,944; WO2004/060669; U.S. Pat. No. 6,627,564; U.S. Pat. No. 6,479,154; U.S. Pat.No. 6,465,073; U.S. Pat. No. 6,313,372; U.S. Pat. No. 6,001460; WO2004/060652; and U.S. Pat. No. 6,849,324.

In some embodiments of the present invention, an elastomer may beprinted onto a nonwoven, film, or laminate, including those describedabove, to form a BSOC. The elastomer may be printed as a film or in apattern. If printed as a pattern, the pattern may be relativelyhomogeneous over the area of the outer cover, i.e., in a net-like or dotpattern, or may comprise regions of relatively higher or lower basisweight wherein the elastomeric component is been applied onto at leastone region of an extensible fibrous substrate to provide stretchproperties to a targeted region of the substrate (i.e., after selectiveincremental stretching). The elastomer may be transferred onto thefibrous substrate through a process such as gravure printing whichprovides a great deal of flexibility relative to the amount of elastomerdeposited as well as the type of patterns that can be achieved. Detailson these embodiments, and further examples of suitable materials andpatterns, are disclosed in US 2005/0214461, WO 2005/097358, and WO2005/097512. Polyolefins blends and polyolefins/styrenic blockcopolymers such as those disclosed above and tailored to possess thedesired rheological characteristics for adequate deposition via gravureprinting represent preferred compositions for the present invention.Other exemplary materials and processes are disclosed in US2005/0106980; U.S. Pat. No. 6,579,274; U.S. Pat. No. 6,503,236; and U.S.Pat. No. 6,264,641.

Regardless of the composition of the biaxially stretchable outer cover,the outer cover material can be mechanically activated in both thelongitudinal and lateral directions via any of the processes describedherein in order to increase the strain range over which the web exhibitsstretch/recovery properties, impart the desirable tactile/aestheticproperties to the material (e.g., a cotton-like texture), and in someembodiments create the higher modulus components of the anchoringsystem, such as linkages or anchoring bands. Mechanical activationprocesses include ring-rolling, SELFing, and other means ofincrementally stretching webs as known in the art. In some embodimentsit may be desirable to (selectively) over-bond (parts of) the outercover (at areas not activated) to further increase the mechanicalstrength of (parts of) the outer cover.

The outer covers of the present invention may additionally comprisegraphics printed on the outside or inside surface of one of the outercover or waist/leg band components or printed on an underlying componentof the article. The graphics may be decorative, educational,entertaining, or instructional. Multiple topically related or unrelatedgraphics may be employed. The graphics may be formed such that they aremost clear or legible when the printed substrate is in a relaxedcondition or when the printed substrate is in an extended condition.Alternatively, some of the graphics may be most clear or legible whenthe printed substrate is in a relaxed condition, while others are mostclear/legible when the printed substrate is in an extended condition. Incertain embodiments, the graphics comprise active graphics, i.e.,graphics which change based on environmental conditions such as elapsedtime, humidity, temperature, wetness, etc. Active graphics may betopically related to each other so as to portray and event or action(e.g., a fish appears or disappears from a character's fishing line).

Core Assembly and Other Components

Referring back to FIG. 1B, in some embodiments, the core assembly 23 mayinclude a topsheet 22, a containment member 28, and an absorbent core 26disposed between the topsheet 22 and the containment member 28. Asshown, the core assembly 23, in some embodiments, may form a bucketshape. The term “bucket-shaped” derives from the appearance of a lateralcross section of the core assembly 23 when the article is configured asit would be when applied to a wearer. The bucket-shaped core assembly 23represents a substantially self-contained core assembly 23 as it maycomprise the topsheet 22, absorbent core elements, a containment member28, and leg cuffs 35, e.g. inner cuff or barrier leg cuffs. As will beappreciated from the description below, it can be said that the coreassembly 23 is self-contained.

The core assemblies suitable for use in the absorbent articles of thepresent invention are not limited to the “bucket shaped” assemblies. Forexample, embodiments are contemplated where the core assembly comprisesan absorbent core, optionally a core wrap, and optionally anacquisition/distribution system (see FIGS. 13A, 14A, 15A, 16, 17, 18,and 19A). One skilled in the art would appreciate that the coreassemblies described herein can be utilized with any suitable anchoringsystem described herein. In the non-bucket embodiments the core issandwiched between the topsheet and the outer cover. Preferably the coreis (partially) force decoupled from the topsheet and the outer cover,i.e. the core can float.

As shown in FIG. 1B, in some embodiments, the containment member 28covers a garment-facing surface of the core 26, at least in part, andextends laterally beyond the core 26. As shown, in some embodiments, thelaterally distal ends of containment member 28 can be connected to aspacing member 30, such as an elastic, that biases a portion of thecontainment member 28 that is disposed laterally outboard of the core 26vertically away from the body-facing surface of the chassis 21. In someembodiments, the spacing members 30 may bias the laterally distal endsvertically outwardly or vertically inwardly from longitudinal side edgesof the core 26.

Some examples of suitable spacing members 30 include elastomeric films,elastomeric foams such as polyurethane foams or cross-linked naturalrubber foams; formed elastic scrim; elastomeric films such as heatshrinkable elastic materials; elastomeric film laminates such as alaminate of a heat-shrinkable elastomeric film and a resilient member;and elastic strands made from rubber, synthetic rubber, elastomericpolyurethane, or other materials.

The laterally distal ends of the containment member 28 can define a pairof opposing and longitudinally extending leg cuffs 35 that extend outfrom the inner-facing surface 50 of the diaper 20 to provide a sealagainst the wearer's body and improve containment of liquids and otherbody exudates. Additionally, the containment member 28 may comprise acentral zone 1500 and a pair of barrier zones 1510. The central zone1500 is a portion of the containment member 28 disposed adjacent (butnot necessarily in face-to-face contact) to the garment-facing surfaceof the absorbent core 26. In some embodiments, longitudinal boundary ofthe central zone 1500 is coterminous with the longitudinal edges of theabsorbent core 26. However, in other embodiments, the longitudinalboundary of the central zone 1500 may be inboard or outboard of thelongitudinal edges of the absorbent core 26. The barrier zones 1510 areportions of the containment member 28 disposed between the central zone1500 and the distal ends of the containment member 28. The barrier zones1510 serve as barrier leg cuffs 35 for the absorbent assembly 23. Inother words, by extending away from the body-facing surface of thechassis 21, the barrier zones 1510 can provide a physical barrier to thefree flow of exudates and provides a structure to contain the exudateswithin the absorbent assembly 23.

In some embodiments, the containment member 28 may additionally providea forming layer on which liquid absorbent material can be depositedduring manufacture of the core assembly 23 and is generally an airpermeable material. The containment member 28 can be a hydrophobicmaterial and can be rendered liquid impermeable, e.g., in the centralzone 1500 and/or barrier zone 1510 of the containment member 28, bycoating at least the garment-facing or the wearer-facing side, or both,of the central zone 1500 and/or the barrier zones 1510 of thecontainment member 28 with an impermeable material. The impermeablematerial may comprise a breathable or non-breathable film or maycomprise an in-situ formed barrier layer such as a hydrophobic coating.The hydrophobic coating may comprise any suitable hydrophobic materialknown in the art. For example, the hydrophobic coating may comprise awax composition, a hydrophobic skin care composition, or materials withsimilar properties, which is applied to the containment member 28 in amolten form and subsequently cooled to form a continuous coating. If atleast the central zone 1500 of the containment member 28 is liquidimpermeable, the outer cover 24 can be constructed as a liquid permeablemember.

If the containment member 28 acts both as a forming substrate for atleast a portion of the absorbent core 26 and as a leg cuff material, itsproperties can be properly balanced. For example, in some embodiments,the containment member 28 can be air permeable in a portion of thecentral zone 1500 and/or the barrier zones 1510 which may allowsufficient control over the process of absorbent material depositionthereon, Subsequent to the deposition of the absorbent material, the airpermeability of the central zone 1500 may be decreased if desired.Additionally, the containment member 28 may be sufficiently impermeableto liquids in barrier zones 1510 to serve as a barrier cuff.Accordingly, in certain embodiments, the central zone 1500 may exhibitan air permeability of about 100 to 300 m³/m²/min at a pressure drop of125 Pa, preferably around 120 to 200 m³/m²/min, as measured according tothe Air Permeability Test provided below. Conversely, it is desirablethat the barrier zone 1510 be liquid impermeable; however, it isbelieved that the degree of air permeability required in the centralzone would harm liquid impermeability. Therefore, the barrier zone 1510may exhibit an air permeability less than that of the central zone 1500.In certain embodiments, the barrier zone 1510 exhibits an airpermeability that is about 10%, about 20%, about 50%, about 75%, orabout 100% less than the air permeability of the central zone 1500.

The barrier zone 1510 may exhibit liquid impermeability for barrierprotection while maintaining air and vapor permeability for wearercomfort. In certain embodiments, the barrier zone 1510 exhibits ahydrohead, as measured according to the Hydrostatic Head (Hydrohead)Pressure Test provided below, of greater than about 10 mbar, 20 mbar,and 40 mbar.

In some embodiments, the constraints on the properties of the basematerial of the containment member 28 may be relaxed by treating aportion of the containment member material to enhance its ability toperform either the core material deposition function (i.e., increase airpermeability) or the barrier cuff liquid containment function (i.e.,decrease liquid permeability). For example, the central zone 1500 may betreated such that its air permeability is increased, enabling it tobetter act as a core material deposition substrate. Alternatively, thebarrier zones 1510 may be treated to make them more liquid impermeableto enhance their liquid barrier functionality as barrier cuffs.

Any suitable treatment known in the art can be utilized to increase airpermeability and/or decrease liquid permeability. Examples of somesuitable treatments include chemical, mechanical, thermal, and othersurface energy modifying treatments, such as plasma treatment (e.g., viacorona discharge, etc.). In one example, the treatment may reduce liquidpermeability by decreasing the surface energy of the material, reducingthe pore size distribution in the web, or occluding the web with aliquid impermeable layer. In another example, the treatment may increaseair permeability by increasing the porosity of the web by mechanicallyinducing hole formation and/or enlargement via aperturing (e.g., pinaperturing, laser aperturing, etc.) or stretching the web (e.g., viatentering, or incremental stretching, e.g. activation, ring-rolling,SELFing). In some embodiments, both the central and barrier zones can betreated as described above. In another example the central cone 1500initially has high air permeability, the absorbent material is depositedonto it (requiring the high air permeability), and afterwards thecentral zone 1500, and potentially zone 1510 are treated to make it lessliquid permeable.

Some examples of suitable chemical treatments include application ofhydrophobic compositions such as hydrophobic skin care compositions,silicones, or any other low surface energy composition as is known inthe art. Some examples of suitable mechanical treatments includetentering, spreading (i.e., in the lateral direction via a spreadingbar), incrementally stretching, e.g. ringrolling and SELFing, abrading,over-stretching (i.e., in the longitudinal direction), aperturing (i.e.,via mechanical means such as pins or dies, lasers, water jets, air jets,and the like), puncturing, hole punching, slitting, microSELFing, andother mechanical treatments as known in the art. Some examples ofsuitable thermal treatments include heated smooth roll calendaring andother thermal means, such as hot air treatments, lasers, radiofrequencyheating, and ultrasonics, to at least partially melt portions of thematerial structure (e.g., fibers) to reduce average pore size. In someembodiments, thermal treatments may be enhanced in embodiments whereinthe barrier layer comprises a multi-component material, such as anonwoven comprising bicomponent fibers wherein one of the components hasa lower melting point than the other. Other suitable treatments for thecentral zone 1500, the barrier zones 1510 and suitable materials andconfigurations for the containment member 28 are discussed in aco-pending patent application entitled “Absorbent Article Having aMultifunctional Containment Member”, filed on behalf of Roe et al. onJun. 7, 2006, having an attorney docket number of 10435P.

In some embodiments, the containment member 28 can be a singlecontinuous material in its lateral dimension. In some embodiments,however, the containment member 28 can comprise two or more separatematerials that overlap and/or abut along their lateral edges and arecombined or bonded to form a composite web. For example, a web of afirst material may form the central zone 1500 of the containment member28, while a web of a second material may form each of the barrier zones1510 of the containment member 28. Or, a web of a second material mayform zone 1500 (e.g. a film), while a web of a first material (e.g. anonwoven) may form zones 1500 and 1510. While the first and secondmaterials may be identical or have similar properties, it may bepreferable that they have properties specific to their intendedfunctions. For example, per the above description, the first materialmay comprise a highly air permeable material while the second materialmay comprise a highly liquid impermeable material. The webs may bebonded via any know method as known in the art as long as thefunctionality of the central and barrier zones is minimally impacted.The webs may be bonded together along their entire lengths.

The containment member 28 may comprise a woven web, a nonwoven web, anapertured film, and a composite or laminate of any of the aforementionedmaterials. The containment member 28 may comprise a nonwoven, fibrousweb that comprises synthetic and/or natural fibers. In certainembodiments, the containment member 28 is an air permeable nonwoven websuch as described in U.S. Pat. No. 4,888,231.

As shown in FIG. 1B, in some embodiments, a core cover 29 can bedisposed on a wearer-facing surface of the core 26 and may helpimmobilize the liquid absorbent material of the absorbent core 26. Thecore cover 29 may generally be a liquid pervious material, such as anonwoven or tissue. In some embodiments, the core assembly 23 mayfurther comprise the topsheet 22 which can be disposed adjacent abody-facing surface of the core cover 29.

The absorbent core 26 may comprise a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. The absorbent core can comprise any absorbent material that isgenerally compressible, conformable, non-irritating to the wearer'sskin, and capable of absorbing and retaining liquids such as urine andother certain body exudates. Examples of suitable absorbent materialsinclude comminuted wood pulp (e.g., air felt creped cellulose wadding,fluff); melt blown polymers including co-form; chemically stiffened,modified or cross-linked cellulosic fibers; wraps and tissue, includingwraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers (such as superabsorbent fibers), absorbentgelling materials, mineral microfibers, and Parez™ bonded wet laidfibers, or any other known absorbent material or combinations ofmaterials. Examples of some combinations of suitable absorbent materialsare fluff with absorbent gelling materials and/or superabsorbentpolymers, and absorbent gelling materials and superabsorbent fibers etc.The absorbent core can further comprise minor amounts (typically lessthan 20% or less than about 10%) of non-liquid absorbent materials, suchas adhesives, waxes, oils, and combinations thereof.

Examples of other suitable absorbent core constructions are described inU.S. Publication No. 2004/0167486 to Busam et al. The absorbent core ofthe aforementioned publication uses no or minimal amounts of absorbentfibrous material within the core. Generally, the absorbent core mayinclude no more than about 20% weight percent of absorbent fibrousmaterial (i.e., [weight of fibrous material/total weight of theabsorbent core]×100).

In certain embodiments the absorbent core may comprise an insert thatmay be removable from the article and replaceable with a fresh, unusedinsert. The insert may be applied to the wearer facing surface of thearticle and held in place via friction, overlapping portions of thearticle, or by a fastener element such as adhesive or a hook/loopfastening element. Alternatively, the insert may be inserted through anopening in the outer surface of the article or at the waist region suchthat the absorbent capacity of the article may be replenished withoutremoving the article from the wearer. The article may also compriseaddition absorbent core elements which may or may not be replaceable.

Regardless of its construction and composition, the absorbent corepreferably contributes to an underwear-like appearance of the article.Since most underwear have no absorbent core, in certain embodiments, thecores of the present invention may be very thin. In these non-limitingembodiments the absorbent core may have a thickness when dry of no morethan about 2 mm, preferably no more than about 1 mm, and generallywithin the range of 0.5 and 1.5 mm. It should be noted that the calliperof the core may vary across its area. At least a portion of the coreshould have the thinness described above; preferably at least about 25%of the total area of the core, more preferably at least about 50% of thetotal area of the core, and most preferably at least about 75% of thetotal area of the core.

Since underwear-likeness is a key aspect of discretion, and sincediscretion is relatively more important for older wearers (i.e.,bedwetting school age children, adults, etc.), the cores of the presentinvention should have relatively high urine capacities. In embodimentsof the present invention intended for wearers older than about 4 yearsof age (i.e., beyond typical toilet training age), the cores preferablyhave a capacity of at least about 500 grams of synthetic urine, morepreferably more than about 700 grams of synthetic urine, and mostpreferably more than about 900 grams of synthetic urine.

In some embodiments, the absorbent core may comprise a fluid acquisitioncomponent which acquires fluid exudates and partitions the exudates awayfrom a wearer's body, a fluid distribution component whichdistributes/redistributes fluid exudates points away from the point ofinitial exudate loading, and/or a fluid storage component which retainsa majority of the fluid exudates on a weight basis. In some embodimentsof the present invention the absorbent core may comprise, in addition tothe storage layer and the durable hydrophilic core wrap, an acquisitionsystem, which comprises an upper acquisition layer facing towards thewearer and a lower acquisition layer. In one embodiment the upperacquisition layer comprises a nonwoven fabric whereas the loweracquisition layer comprises a mixture of chemically stiffened, twistedand curled fibers, high surface area fibers and thermoplastic bindingfibers. In other embodiments, both acquisition layers are provided froma non-woven material, which can be hydrophilic. The acquisition layer isin direct contact with the storage layer. Furthermore, the storage layeror parts thereof, such as the upper acquisition layer, can optionally becoated with a hydrophilicity boosting composition.

An example of a suitable absorbent core comprising an acquisition layer,a distribution layer, and/or a storage layer is described in U.S. Pat.No. 6,013,589. Other exemplary absorbent core configurations arediscussed in U.S. Patent Application Publication No. 2003/0225382A1;U.S. application Ser. No. 11/329,797, entitled, “End Seal For anAbsorbent Core”, filed on Jan. 11, 2006; and U.S. application Ser. No.11/329,796, entitled, “Sealed Core For An Absorbent Article”, filed onJan. 11, 2006. Yet other exemplary absorbent structures for use as theabsorbent assemblies are described in U.S. Pat. No. 4,834,735, entitled“High Density Absorbent Members Having Lower Density and Lower BasisWeight Acquisition Zones”, issued to Alemany et al. on May 30, 1989; andU.S. Pat. No. 5,625,222 entitled “Absorbent Foam Materials For AqueousFluids Made From high Internal Phase Emulsions Having Very HighWater-To-Oil Ratios” issued to DesMarais et al. on Jul. 22, 1997.

The components of the core assembly 23 can be joined as described viaany suitable adhesive or cohesive. While adhesive or cohesive can beused to connect various absorbent article components as illustrated anddescribed herein, one having ordinary skill in the art will appreciatethat any suitable alternative attachment mechanism can facilitate suchconnections. Examples of suitable alternatives include, but are notlimited to, thermal bonds, RF (radio frequency) bonds, pressure bonds,ultrasonic bonds, welds, stitching, and the like. Any of theaforementioned layers of the core assembly 23 can comprise a singlematerial or may comprise a laminate or other combination of two or morematerials.

In conventional absorbent articles, cores are typically not stretchable.Because the outer cover can be biaxially stretchable, it may bebeneficial to render the core stretchable, at least in the longitudinaldirection. This will allow the product length to be reduced, while stillbeing able to fit all the wearers in a given size. The core can berendered stretchable in one of several ways. For example, the componentsthat make up the core could be inherently stretchable, e.g. stretchablenonwovens. As another example, the core may comprise folds in thelongitudinal direction, which unfold when the product is stretched. Asanother example, the core may comprise two separate parts, a front halfand a back half, with some overlap in the crotch region, the first waistregion, or the second waist region. As the diaper stretches, the twoparts of the core slide past each other, decreasing the degree ofoverlap. It should be appreciated, however, that the core need not bestretchable for an absorbent article to suitably conform to the wearer'sbody in accordance with the principles of the present invention.

In certain embodiments, the chassis 21 provides the main structure ofthe diaper 20 with other features added to form the composite diaperstructure. While the topsheet 22, the outer cover 24, and the coreassembly 23 can be assembled in a variety of well-known configurations,certain diaper configurations are described generally in U.S. Pat. Nos.3,860,003; 5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and6,004,306. Topsheet 22, outer cover 24, and absorbent core 26 arediscussed in more detail below.

Furthermore, while the topsheet 22, the outer cover 24, and theabsorbent core 26 can include many different materials and can beassembled in a variety of well known configurations, suitable diapermaterials and configurations are described generally in U.S. Pat. No.3,860,003 entitled “Contractible Side Portions for Disposable Diaper”which issued to Kenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No.5,151,092 issued to Buell on Sep. 9, 1992; and U.S. Pat. No. 5,221,274issued to Buell on Jun. 22, 1993.

As described herein, the topsheet 22 is generally a portion of thediaper that can be positioned at least in partial contact or closeproximity to a wearer. Accordingly, the topsheet can be supple, softfeeling, and non-irritating to a wearer's skin. Generally, at least aportion of the topsheet is liquid pervious, permitting liquids (e.g.,urine) to readily penetrate through its thickness. The topsheet can bemade of a hydrophobic material to isolate the wearer's skin from liquidscontained in the absorbent core. Suitable topsheets can be manufacturedfrom a wide range of materials, such as porous foams; reticulated foams;apertured plastic films; or woven or nonwoven webs of natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers), or a combination of natural and synthetic fibers.A suitable topsheet is available from BBA Fiberweb, Brentwood, Tenn. assupplier code 055SLPV09U. Other examples of suitable topsheets 22 aredescribed in U.S. Pat. No. 3,929,135, issued to Thompson on Dec. 30,1975; U.S. Pat. No. 4,324,246 issued to Mullane et al. on Apr. 13, 1982;U.S. Pat. No. 4,342,314 issued to Radel et al on Aug. 3, 1982; U.S. Pat.No. 4,463,045 issued to Ahr et al. on Jul. 31, 1984; and U.S. Pat. No.5,006,394 issued to Baird on Apr. 9, 1991. Other suitable examples ofmaterials suitable for use as a topsheet are described in U.S. Pat. No.5,916,661; U.S. Pat. No. 6,680,422B2; U.S. Pat. No. 5,342,338; and U.S.Patent Application Publication No. 2003/0021951A1.

In the various embodiments discussed above, the topsheet can span theentire range from being completely non-stretchable to being biaxiallyelastic. This covers extensibility in the lateral direction,longitudinal direction, or both the lateral and longitudinal directions,extensibility in one direction and elasticity in the other direction,and elasticity in one or both directions. In accordance with certainaspects of the invention, particularly considering manufacturing costs,it may be desired to confine all the elastic stretch (recoverablestretch) to just the outer cover.

Alternatively, the topsheet can be rendered stretchable (extensible orelastic) by any of the methods known in the art, including incrementalstretching, stretch bonding, neck bonding, and the like. Anon-stretchable topsheet can be made extensible in the lateral directionduring fabrication by incrementally stretching in the lateral direction,maintaining enough longitudinal tension in the web in order to preventthe web from spreading out, and bonding the topsheet to the outer coverand core of the diaper while the width of the web is maintained.Extensibility or slack can be built into a non-elastic topsheet in thelongitudinal direction by pre-stretching a shorter, elastic outer coverin the longitudinal direction to make it the same length as the longertopsheet, bonding the two together at least in some areas, and allowingthe outer cover to retract. This produces regions in the topsheet thatare gathered in the longitudinal direction, thus allowing the diaper tostretch up to the full length of the topsheet without the topsheetoffering any significant resistance.

The topsheet can be rendered elastic using any of the methods known inthe art, including stretch bonding, neck bonding incremental stretching,and the like. The preferred options for making an elastic topsheet aresimilar to those used to make the elastic outer cover.

The topsheet can be made stretchable in one direction or biaxiallystretchable by any of the methods known in the art. In accordance withcertain aspects of the present invention, the topsheet can be renderedbiaxially elastic. For example, the topsheet could be an elastomericnonwoven formed from a mixture of elastomeric and non-elastomericfibers/filaments. Incrementally stretching the nonwoven releases thestretch properties. An alternative approach would be printing anelastomeric composition onto an extensible substrate, followed byincremental stretching if desired. Yet another approach is to print anelastomeric composition onto an elastomeric nonwoven or film.

Any portion of the topsheet can be coated with a lotion as is known inthe art. Examples of suitable lotions include those described in U.S.Pat. Nos. 5,607,760; 5,609,587; 5,635,191; and 5,643,588. The topsheetcan be fully or partially elasticized or can be foreshortened so as toprovide a void space between the topsheet and the core. Exemplarystructures including elasticized or foreshortened topsheets aredescribed in more detail in U.S. Pat. Nos. 4,892,536; 4,990,147;5,037,416; and 5,269,775.

For example, the diaper may also include a waistband 43 (see FIG. 1A)that can generally form at least a portion of the end edge 56 of thediaper 20. The waistband 43 is that portion or zone of the diaper 20which is intended to elastically expand and contract to dynamically fitthe wearer's waist, and that helps provide improved fit and containment.The elastic waistband 43 can include a segment positioned in the frontwaist region 36 and/or back waist region 38, and can be discretelyattached or an integral part of the chassis 21. Examples of suitablewaistbands include those described in U.S. Pat. No. 4,515,595; U.S. Pat.No. 5,151,092; and U.S. Pat. No. 5,221,274.

The diaper can also include a leg band or leg elastic that helps provideimproved fit and containment, as is appreciated by one having ordinaryskill in the art. The leg band is that portion or zone of the diaper 20,which is intended to elastically expand and contract to dynamically fitthe wearer's leg. Leg elastics may include several different embodimentsfor reducing the leakage of body exudates in the leg regions. Legelastics and contractible leg openings are discussed in U.S. Pat. No.3,860,003; U.S. Pat. No. 4,909,803; U.S. Pat. No. 4,695,278; and U.S.Pat. No. 4,795,454.

Alternatively, the waist and/or leg bands may comprise a separateelement discretely affixed to the inner or outer surface of the articlein proximity to the lateral or longitudinal edges of the article. Theseparate element is preferably elastomeric and more preferablypre-tensioned prior to attachment to the article so as to provide acontracted waist and/or leg feature. The waist and/or leg band elementsmay comprise a zero-strain laminate or a pre-stretched laminate, a film,a foam, or an elastic nonwoven. If a laminate, the separate elementpreferably additionally comprises at least one elastomeric element suchas an elastomeric film, a printed elastomeric pattern, elastic strands,or an elastic nonwoven or foam. The distal edge of the waist and/or legband may be aligned with the distal edge of the article, may extendbeyond the edge of the article, or may terminate inboard of the articleedge. In certain embodiments, the waist and/or leg band may at leastpartially wrap around the edge of the article and may be bonded to boththe inner and outer surfaces of the article, or a component thereof.

Additionally, in some embodiments, the diaper 20 may comprise finishedouter leg cuffs. Finished outer leg cuffs and waist edges are discussedin U.S. Pat. No. 5,797,824 and U.S. Pat. No. 7,013,941, while the latteralso discusses methods and an apparatus for applying the material.

In certain alternative embodiments, the waist edge may be nonparallel tothe lateral centerline of the article. Nonlinear waist edges may beconvex or concave relative to the lateral centerline, or may haveportions which are concave and other portions which are convex relativeto the lateral centerline. The waist edge is preferably symmetricrelative to the longitudinal centerline, but embodiments arecontemplated having a waist edge asymmetric relative to the longitudinalaxis.

Additionally, in some embodiments, in order to provide more comfort andfit to the wearer, the leg elastics may be joined to the chassis 21 ofthe diaper 20 such that the leg elastics are curved. In someembodiments, the elastics can be applied in a direction which isgenerally parallel to the longitudinal centerline. In some embodiments,the leg elastics can be applied in a curvilinear configuration. The legelastics may be joined to the chassis 21 in any suitable manner known inthe art whether the leg elastics are curved or otherwise.

Referring now to FIG. 9, when the diaper 20 is configured as a pull ondiaper, the diaper 20 is worn on the lower torso of a wearer. As shown,when a first side panel 902 is joined to a second side panel 904, theend edges 56 encircle the waist of the wearer while, at the same time,the chassis side edges 54 define leg openings that receive the legs ofthe wearer. The crotch region 37 (shown in FIG. 1A) is generallypositioned between the legs of the wearer, such that the absorbent core26 extends from the front waist region 36 through the crotch region 37to the back waist region 38.

In some embodiments, the first and/or second side panel 902 and 904, canbe formed of discrete separate elements affixed to the diaper 20. Insome embodiments, the first and/or second side panel 902, 904, can beformed from a unitary piece of material that is neither divided nordiscontinuous with an element of the diaper 20. For example, in someembodiments, the side panels may comprise a portion of a topsheet. Asanother example, the side panels may comprise a portion of a backsheet.As yet another example, the side panels may comprise a portion of abarrier leg cuff (discussed hereafter).

The side panels 902 and 904 can be extensible or can be elasticallyextensible. While extensible side panels may be constructed in a numberof configurations, examples of diapers with extensible side panels aredisclosed in U.S. Pat. No. 4,857,067, entitled “Disposable Diaper HavingShirred Ears” issued to Wood, et al. on Aug. 15, 1989; U.S. Pat. No.4,381,781 issued to Sciaraffa, et al. on May 3, 1983; U.S. Pat. No.4,938,753 issued to Van Gompel, et al. on Jul. 3, 1990; in U.S. Pat. No.5,151,092 issued to Buell et al. on Sep. 29, 1992; U.S. Pat. No.6,677,258 issued to Carroll et al. on Jan. 13, 2004; U.S. patentapplication Ser. No. 10/396,977 filed on Mar. 25, 2003, U.S. Pat. No.5,580,411 entitled “Zero Scrap Method For Manufacturing Side Panels ForAbsorbent Articles” issued to Nease, et al. on Dec. 3, 1996; and U.S.Pat. No. 6,004,306 entitled “Absorbent Article With Multi-DirectionalExtensible Side Panels” issued to Robles et al. on Dec. 21, 1999.

The diaper 20 can be preformed by the manufacturer to create a pull-ondiaper or pant. Specifically, the diaper 20 may include left and rightclosed side seams 34, each disposed at regions proximal the front andback ends of side edges 54. Each side seam 34 can be closed bybuttressing and subsequently attaching a given side edge 54 in the frontand back waist regions 36 and 38 either using a permanent seam orrefastenable closure member. It should be appreciated that side edgescan alternatively be attached in an exterior surface-to-exterior surfaceconfiguration, interior surface-to-interior surface configuration, orinterior surface-to-exterior surface (overlapping) configuration.

Because the diaper 20 is configured as a pull-on diaper, both side seams34 can be closed prior to the application of the article to a wearer. Insome embodiments, the diaper 20 can be configured such that the diaper20 is prefastened by the manufacturer, i.e. the caregiver or wearer doesnot have to fasten the diaper 20 upon removal of the diaper from apackage 40 (shown in FIG. 10). In some embodiments, the diaper 20 can beunfastened in the package 40, i.e. the caregiver or wearer fastens thediaper 20 prior to donning the diaper 20 on the wearer such that thediaper 20 is configured as a pull-on.

The side seams 34 can be closed in accordance with any known techniquesor methods known in the art. For instance, the seams 34 can be formedwith a permanent seam, which can include a bond formed by heat sealingsuch as ultrasonic bonding, high pressure bonding, RF (radio frequency)bonding, hot air bonding, heated point bonding, and the like asappreciated by one having ordinary skill in the art.

As another example, the side seams 34 may comprise fastening elementswhich are refastenable. The fastening elements may comprise anyrefastenable fastening elements known in the art. For example, thefastening elements may comprise hook and loop fasteners, hook and hookfasteners, macrofasteners, tape fasteners, adhesive fasteners, cohesivefasteners, magnetic fasteners, hermaphrodidic fasteners, buttons, snaps,tab and slot fasteners, and the like. Some suitable examples offastening systems and/or fastening elements are discussed in U.S. Pat.Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;5,221,274; 6,432,098; U.S. patent application Ser. No. 11/240,943,entitled, “Anti-Pop Open Macrofasteners” filed on Sep. 30, 2005; U.S.patent application Ser. No. 11/240,838, entitled, “A Fastening SystemHaving Multiple Engagement Orientations”, filed on Sep. 30, 2005.Additionally, various suitable pant configurations are disclosed in U.S.Pat. No. 5,246,433; U.S. Pat. No. 5,569,234; U.S. Pat. No. 6,120,487;U.S. Pat. No. 6,120,489; U.S. Pat. No. 4,940,464; U.S. Pat. No.5,092,861; U.S. Pat. No. 5,897,545; U.S. Pat. No. 5,957,908; and U.S.Patent Publication No. 2003/0233082 A1 (published on Dec. 18, 2003 toMark J. Kline, et al.).

In other embodiments, secondary fasteners may be employed to enableadjustment of the article once the article has been applied to a wearer.Secondary fasteners serve to increase the tension (i.e., “cinch”) in thewaist hoop subsequent to application in order to provide enhancedsustained fit of the article. Secondary fasteners may include any typeof fastener as known in the art and may be associated with a stretchelement that aids in increasing the tension in the waist hoop.

Alternatively, the closed side seams 34 can be formed as disclosed inU.S. Pat. No. 5,779,831; U.S. Pat. No. 5,772,825; U.S. Pat. No.5,607,537; U.S. Pat. No. 5,622,589; U.S. Pat. No. 5,662,638; U.S. Pat.No. 6,042,673; and U.S. Pat. No. 6,726,792. The aforementioned patentsdisclose various processing methods to provide absorbent pull-ondiapers. One of the processes utilizes a final knife followed by areciprocating tucker blade that pushes the pad from a horizontalorientation to a vertical orientation and a vacuum conveyor belt thatholds the pad through a high pressure side seaming unit. The sideseaming unit is followed by a slitter that trims the pant edges toprovide a finished seam edge. An alternative method disclosed in theaforementioned patents involves cutting the pad in the final knife andbi-folding the pad collecting the pads in a “waterwheel” stacker (arotary slotted wheel). The bonding is accomplished while the pad is heldin place on the rotating wheel.

The present invention therefore recognizes that a plurality of pull-ondiapers 20 can be pre-formed with closed side seams 34 and subsequentlypackaged and delivered to a user to prevent the need for the user (whichcould be the wearer) to close the side edges 54 prior to securing thediaper 20 on the wearer. Accordingly, referring to FIG. 10, the presentinvention includes the method of providing a plurality of pull-ondiapers 20 of the type described above, and placing the diapers 20 intoa closed package 40 that retains the diapers 20. Accordingly, when theend user opens the packaging 40, the pull-on diaper 20 can be donned onthe wearer more easily than conventional taped diapers. Embodimentscomprising taped diapers are discussed hereafter.

Other Embodiments

One having ordinary skill in the art will appreciate that the anchoringsystem 42 of the present invention can assume many alternativeconfigurations that decouple forces from the core and the outer coverand direct the decoupled forces to the wearer's hip region. It will thusbe apparent that any of the features of anchoring system elements (e.g.,the circumferential anchoring member, anchoring members, and the LDEs)can be combined in any desired manner in accordance with the principlesof the present invention. Some additional embodiments of anchoringsystems have been provided heretofore. Still other exemplary embodimentsfollow.

Additionally, one of ordinary skill in the art will appreciate that theanchoring system can be adapted to a number of different core assemblyconfigurations and diaper configurations. For example, diapersconstructed in accordance with the present invention may compriseadditional elements from those discussed heretofore. Some exemplary coreassembly and diaper assembly configurations are provided hereafter.

With regard to FIGS. 11 and 12A, in some embodiments, the diaper 20 mayfurther comprise a stretchable waist cover 1523 which may be attached tothe diaper 20 in the first waist region 36 and/or the second waistregion 38. The waist cover makes it possible to effectively manage theedges of the discrete core bucket when the core bucket is not attachedto the outer cover along its full length, but only in a narrow region inthe center. Without the waist cover, the edges of the core bucket wouldneed to be bonded to the outer cover, thus compromising outer coverstretch. As shown in FIG. 11, in some embodiments, the waist cover 1523can be full width, e.g. extending from the first side edge 54 to thesecond side edge 54 in the first waist region 36 and/or the secondregion 38. A full width waist cover 1523 may be joined to a portion ofthe core assembly 23 proximate to an end of the core assembly 23, may bejoined to the chassis 21 adjacent to the side edges 54, and/or may bejoined to the waistband 43.

As shown in FIG. 12A, in some embodiments, the waist cover 1523 mayextend laterally about the same width as the core assembly 23. The waistcover 1523, as shown in FIG. 12A, in some embodiments, may be joinedproximate to an end of the core assembly 23 and/or the waistband 43. Inone specific embodiment, the diaper 20 may comprise the waist cover 1523which has a width which is generally about equal to the width of thecore assembly 23. In an alternate embodiment, the waist cover is formedby a discrete waistband attached to the inner surface of the article andextending longitudinally inboard a sufficient distance to cover thelongitudinal ends of the core. In this embodiment, the waistband may bebonded to the outer cover proximate the waist edge and along itslongitudinal edges, but not to the core assembly. In a further alternateembodiment wherein the core assembly comprises a “bucket” constructionand wherein the bucket core assembly has a longitudinal dimensionsmaller than the longitudinal dimension of the article, the waist covermay comprise an extension of the topsheet portion of the bucket coreassembly affixed to the outer cover proximate the waist edge of thearticle. In this embodiment, lateral extensibility in the waist coverregion is provided via use of an extensible topsheet and/or mechanicalactivation (incremental stretching) of the portion of the topsheetextending beyond the bucket core assembly.

The waist cover 1523 may have several functions. For example, the waistcover 1523 may prevent the ends of the core assembly 23 disposed nearestto the first waist region 36 and the second waist region 38, which maynot be bonded to the outer cover 24, from flipping over or bucklingduring product application/wearing. It should be noted that by notlocking the stretchable outer cover 24 down with the longitudinal endsof the core assembly 23, the diaper 20 may be capable of more stretch inthe longitudinal direction, and thus capable of providing a betterconforming fit. As another example, the waist cover 1523 may improveaesthetics by hiding any non-bonded ends of the core assembly 23. As yetanother example, the anchoring bands 44′, 44″, and/or LDEs 46 can beattached to the waist cover 1523 instead of the outer cover 24, thussignificantly improving outer cover 24 aesthetics and productconformity, especially in the longitudinal direction. In someembodiments, the anchoring bands 44′, 44″, and/or the LDEs 46, or aportion thereof, can be integral with the waist cover 1523. For example,portions of the waist cover 1523 which are not the anchoring bands 44′,44″, and/or the LDEs 46 may be incrementally stretched more so than theanchoring bands 44′, 44″, and/or the LDEs 46. The waist cover 1523 canbe treated as described above with regard to the integral formation ofthe anchoring system in the outer cover.

In some embodiments, the waist cover 1523 can be stretchable in at leastone direction (lateral or longitudinal), preferably in both. Also, insome embodiments, the waist cover 1523 may be elastic. The waist covers1523 may utilize any suitable material known in the art. Some suitableexamples of material suitable for use as the waist cover 1523 includesome of the examples provided for the outer cover 24. Additionally, thewaist covers 1523 may have the same properties as the outer cover 24described heretofore, e.g. force at 15% strain and % set (per theHysteresis Test provided hereafter). Additionally, the waist covermaterial 307 is preferably a skin friendly, soft, and liquid permeable,stretchable in machine direction material. Suitable materials areactivatable nonwoven and apertured nonwoven material as described inU.S. Pat. Nos. 5,342,338 6,680,422B2.

The anchoring bands 44′ and/or 44″ can be partly or fully attached toeither the waist cover 1523 or the outer cover 24 or both, in someembodiments. For example, anchoring band 44′ may be attached to theouter cover 24, while anchoring band 44″ may be attached to the waistcover 1523, or vice versa. One skilled in the art will appreciate thatthe anchoring bands 44′ and 44″ can be positioned at the desiredlocation on the wearer's body to carry the desired level offorce/modulus regardless of whether the anchoring bands are partially orfully attached to the waist cover 1523, the outer cover 24, or both.

In order to manage the edges of the core bucket, in some embodiments, acarrier web may be attached to the core bucket, the carrier web beingthe full length of the product. The carrier web is extensible in eitherthe lateral or longitudinal direction, or both. The carrier web may alsobe elastic. The carrier web may be a nonwoven or a film. In someembodiments, the carrier web is incrementally stretched at least at oneof the two longitudinal ends in and near the waist band area, or evenover substantially all of the carrier web. This incremental stretchingmay be done prior to or after bonding the carrier web to the outer coverin the waist band area. This carrier web may be attached to the garmentfacing side of the core bucket or anywhere inside the core bucket. Thiscarrier web is longer than the core bucket and either the same as orless than the length of the outer cover. In the embodiment of FIG. 12B,an absorbent article 1202 has a chassis 1211-2, an outer cover, acarrier web 1218-2, and an absorbent core 1290-2 with ends 1290-E-2. Theouter cover has an outer cover length 1207-2-L, which is about the sameas a carrier web length 1218-2-L of the carrier web 1218-2. The carrierweb 1218-2 includes activated regions 1218-A-2. The carrier web 1218-2is attached to the outer cover at locations 1218-B-2.

In some embodiments, one of the components of the core bucket may servethe function of the carrier web. For example, either the topsheet (orbody side liner), or the breathable polyethylene film, or the barrierleg cuff or combinations thereof may be made longer than the core bucketand incrementally stretched at the longitudinal ends. These componentsof the core bucket that are about the length of the product are thenattached to the outer cover in the waist band area. In the embodiment ofFIG. 12C, an absorbent article 1203 has a chassis 1211-3, an outercover, a full-length topsheet 1205-3, and an absorbent core 1290-3 withends 1290-E-3. The outer cover has an outer cover length 1207-3-L, whichis about the same as a topsheet length 1205-3-L of the full-lengthtopsheet 1205-3. The full-length topsheet 1205-3 includes activated ends1205-A-3 past the ends 1290-E-3 of the absorbent core 1290-3. Thecarrier web 1218-2 is attached to the outer cover at location 1218-B-3.

With regard to FIGS. 13A-13C, an absorbent article 120 is illustrated inaccordance with an alternative embodiment, wherein reference numerals ofelements illustrated in FIGS. 13A-13C correspond to like elements ofFIGS. 1A-1C and are incremented by 100 for the purposes of clarity andconvenience.

The absorbent article 120 may be constructed similar to the absorbentarticle 20. However, in some embodiments, the chassis 121 may include aliquid pervious topsheet 122, and a liquid impervious outer cover 124joined to the topsheet 122 proximal the lateral end edges 156 and thelongitudinal side edges 154 via any suitable adhesive or cohesive 132.As described above, the outer cover 124 can advantageously bestretchable in one or more directions, preferably biaxially stretchable,and more preferably biaxially elastic, thereby enhancing both thecomfort of the diaper 120 on the wearer and the conformability to thewearer's anatomy during movement.

A core assembly 123 may include an absorbent core 126 that is positionedbetween the topsheet 122 and the outer cover 124. In some embodiments,the outer cover 124 and the topsheet 122 are stretchable, either axiallyor biaxially; and the core 126 can be said to “float” between thetopsheet 122 and the outer cover 124. In some floating core embodiments,the core, or any components of the core, may not be bonded to thetopsheet and/or outer cover. In other floating core embodiments, thecore is bonded to the topsheet and/or outer cover over a limited portionof its surface area so as to maximize the “underwear-like” nature of theouter cover (i.e., the outer cover is substantially decoupled from thecore or loads generated by the core or contents thereof). For example, afloating core may be bonded to the topsheet and/or outer cover over lessthan 50% of its surface area, and preferably less than 25% of itssurface area. The floating cores of the present invention may be bondedto the topsheet and/or outer cover over an area between about 2 percentand about 20 percent of the core surface area. The absorbent core 126can be disposed symmetrically or asymmetrically with respect to eitheror both of the longitudinal centerline 200 and the lateral centerline210. For example, as shown in FIG. 13A, the absorbent core 126 issymmetrical with respect to both the longitudinal centerline 200 and thelateral centerline 210.

As shown in FIG. 13B, the topsheet 122 can be disposed adjacent thebody-facing surface of the absorbent core 126, while the outer cover 124can be disposed adjacent the garment-facing surface of the absorbentcore 126. The topsheet 122 can be (partially) attached to the core 126via the adhesive or cohesive 132 or any suitable means known in the art.In another embodiment the topsheet 122 and outer cover 124 are notdirectly attached to the core. Rather the core is only connected to theouter cover and the topsheet via the LDE(s) and the CAM(s). In thisexecution it may be desirable to reduce the coefficient of friction ofthe core against the topsheet and/or the coefficient of friction of thecore against the outer cover. In one embodiment, the outer cover 124 issubstantially impervious to liquids. It should be appreciated that thetopsheet 122 can be attached to the core 126 and/or the outer cover 124and that the outer cover 124 can be attached to the core 126 and/or thetopsheet 122.

It should be further recognized that other structures, elements, orsubstrates can be positioned between the core 126 and the topsheet 122and/or outer cover 124. For instance, the core 126 can be disposedbetween the topsheet 122 and a breathable liquid impermeable film formedfrom polyethylene or the like. In such an embodiment, the outer cover124 could be pervious to liquids, as described above with reference toFIG. 1A.

As shown in FIG. 13A, in some embodiments, the topsheet 122 and theouter cover 124 have length and width dimensions generally larger thanthose of the absorbent core 126. The topsheet 122 and the outer cover124 can extend beyond the lateral and longitudinal edges of theabsorbent core 126 to form the periphery of the diaper 120. While thetopsheet 122, the outer cover 124, and the absorbent core 126, caninclude many different materials and can be assembled in a variety ofwell known configurations, suitable diaper materials and configurationsare described generally in U.S. Pat. No. 3,860,003 entitled“Contractible Side Portions for Disposable Diaper” which issued toKenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No. 5,151,092 issued toBuell on Sep. 9, 1992; and U.S. Pat. No. 5,221,274 issued to Buell onJun. 22, 1993.

The topsheet 122 can be configured in a similar manner to the outercover 124. Additionally, in some embodiments, the anchoring system 142of the present invention may be integral with the topsheet 122. Forexample, portions of the topsheet 122 which do not comprise a portion ofthe anchoring system 142 can be mechanically activated to a greaterextent than portions of the topsheet 122 comprising the anchoring system142. The topsheet 122 can be treated as described above with regard tothe integral formation of the anchoring system in the outer cover.

The diaper 120 can further include a pair of opposing and longitudinallyextending barrier leg cuffs 135 that extend out from the innerbody-facing surface 150 of the chassis 121 to provide a seal against thewearer's body and improve containment of liquids and other bodyexudates. Each barrier leg cuff 135 can include several differentembodiments for reducing the leakage of body exudates in the legregions. Some suitable examples of barrier leg cuffs are discussed inU.S. Pat. No. 3,860,003; U.S. Pat. No. 4,909,803; and U.S. Pat. No.4,695,278.

In some embodiments, the barrier leg cuffs 135 can be generally parallelto the longitudinal centerline 200 of the diaper 120. However,embodiments are contemplated where the barrier leg cuffs 135 are curvedoutward. For example, the spacing between the barrier leg cuffs 135 maybe less in the crotch region 137 and more in the waist regions 136 and138.

The diaper 120 may further comprise a waistband 143 that helps provideimproved fit and containment, as is appreciated by one having ordinaryskill in the art. The waistband 143 may be configured similar to thewaistband 43 described heretofore. In contrast, embodiments arecontemplated where the anchoring bands 144′ and/or 144″ generally format least a portion of the end edge 156 of the diaper 120.

Disposable diapers are often constructed so as to have at least oneelastic waistband 143 positioned in the front waist region 136 and/orback waist region 136. Furthermore, while in some embodiments theelastic waistband 143 or any of its constituent elements can include aseparate element affixed to the diaper 120, the waistband 143 need notbe separately affixed to the diaper 120. For instance, the elasticwaistband 143 can be constructed as an extension of other elements ofthe diaper 120 such as the outer cover 124, the topsheet 122 or both theouter cover 124 and the topsheet 122. Examples of suitable waistbandsinclude those described in U.S. Pat. No. 4,515,595; U.S. Pat. No5,151,092; and U.S. Pat. No. 5,221,274.

The diaper 120 also includes a leg band or leg elastic that helpsprovide improved fit and containment, as is appreciated by one havingordinary skill in the art. The leg band is that portion or zone of thediaper 120, which is intended to elastically expand and contract todynamically fit the wearer's leg. Leg elastics may include severaldifferent embodiments for reducing the leakage of body exudates in theleg regions. Leg elastics and contractible leg openings are discussed inU.S. Pat. No. 3,860,003; U.S. Pat. No. 4,909,803; U.S. Pat. No.4,695,278; and U.S. Pat. No. 4,795,454.

Additionally, in some embodiments, in order to provide more comfort andfit to the wearer, the leg elastics may be joined to the chassis 121 ofthe diaper 120 such that the leg elastics are curved. In someembodiments, the elastics can be applied in a direction which isgenerally parallel to the longitudinal centerline. In some embodiments,the leg elastics can be applied in a curvilinear configuration. Theelastics may be applied to the chassis 121 by any suitable means knownin the art.

The diaper 120 further includes an anchoring system 142 (shown in FIG.13A) of the type described above with reference to FIGS. 1A-1C that isintended to fit to the pelvic region of the torso and that supports thecore 126 and central chassis 121, and directs the load forces to atleast a portion of the wearer's waist region where the forces can becoupled into the wearer's body. During wear, the waist and legperimeters, 156 and 154, respectively, move with the parts of the body(spine and legs, respectively) that can move relative to the pelvis.Thus these perimeters can move relative to the anchoring system 142,which, in turn, changes the distances between the perimeters and theanchoring system 142. The waist and leg perimeters can be mechanicallyisolated from the anchoring system 142 by a bi-axially stretchable outercover 124, “BSOC”, and or a biaxially stretchable topsheet, bothdesigned to minimize forces that arise between the waist or legperimeters and the anchoring system from movement of the legs and spinerelative to the pelvis.

As shown in FIGS. 13A-13C, the diaper 120 may further comprise a pair ofanchoring bands 144′ and 144″ which can form a circumferential anchoringmember as described heretofore with regard to the CAM 44A (shown in FIG.2A). In some embodiments, the anchoring bands 144′ and/or 144″ can beattached to the wearer-facing surface of the outer cover 124 via anysuitable adhesive or cohesive. When the diaper 120 is preformed in to apant, the anchoring bands 144′ and 144″ are operatively connected viathe side seam or closure member to form the continuous circumferentialanchoring member that circumscribes the wearer's lower torso region.

As shown in FIG. 13A, the diaper 120 may further comprise a plurality ofLDEs 146. For example, as shown, two LDEs 146 may be disposed in thefirst waist region 136 extending outward from the core 126 toward theirrespective side edges 154. Similarly, two LDEs 146 may be disposed inthe second waist region 138 extending outward from the core 126 towardtheir respective side edges 154. Additionally, the LDEs 146 can extendlaterally outward from the core 126 and toward the corresponding endedge 156 and terminate at opposing ends that can be joined to the inner(i.e., body-facing) surface or the outer-facing surface of thecircumferential anchoring member at the connection zones 148.

In the embodiment illustrated in 13A-13C, the LDEs 146 may be joined tothe garment-facing surface of the core 126 at attachment zones 148. TheLDEs 146 may be joined to the core 126 by any suitable means known inthe art. For example, the LDEs 146 may be joined to the core 126 by anysuitable adhesive, cohesive, or the like. Alternatively, the LDEs 146can be joined to the wearer-facing surface of the core 126.

In the embodiment illustrated in FIG. 13A, the topsheet 122 can bejoined to the outer cover 124 along the perimeter of the absorbentarticle 120 with an adhesive. Alternatively, the topsheet 122 can bejoined to the outer cover 124 in any area in which the topsheet 122 andouter cover 124 overlap, so long as the bonded area lies outside thecore 126. However, the bonds should be constructed such that movement orotherwise suitable operation of the anchoring system 142 is unencumberedand, preferably, such that the bonded region remains stretchable

As described above, the anchoring bands 144′ and/or 144″ can be attachedto the body facing side of the outer cover 124, as illustrated in FIG.13C. This outer cover 124 can be formed from a nonwoven or a laminate ofa nonwoven and a water-impermeable, breathable film. If the outer cover124 is formed of multiple layers 164, 162, e.g. breathable film andnonwoven, the CAM or a portion thereof, e.g. anchoring band 144″ couldalternatively be embedded in between these two layers as illustrated inFIG. 13D. The CAM or a portion thereof, e.g. anchoring band 144″, canalso be either attached on one side of the topsheet 122 as illustratedin FIG. 13E, or embedded between two layers that are part of amulti-layered topsheet. The CAM or a portion thereof can be attached tothe topsheet 122 and/or outer cover 124 at discrete locations or can befully attached as appreciated by one having ordinary skill in the art.Partial bonding of the CAM to the topsheet 122 or outer cover 124 mayallow the CAM to stretch more freely.

A suitable outer layer 162 (shown in FIG. 13D) is available from CorovinGmbH, Peine, Germany as supplier code A18AH0, and a suitable inner layer164 is available from RKW Gronau GmbH, Gronau, Germany as supplier codePGBR4WPR. While a variety of outer cover configurations are contemplatedherein, it would be obvious to those skilled in the art that variousother changes and modifications can be made without departing from thespirit and scope of the invention.

With regard to FIG. 13D, where the outer cover 124 comprises abi-laminate, the outer layer 162 can be made of a soft, non-wovenmaterial, while the inner layer 164 can be made of a substantiallyliquid-impermeable film. The outer layer 162 and the inner layer 164 canbe attached together by adhesive or any other suitable material ormethod. Accordingly, in some embodiments, the CAM or portion thereof,e.g. anchoring band 144″, can be joined to the inner surface of theinner layer 164.

If the inner layer 164 is liquid-impermeable, then the outer layer 162need not be liquid-impermeable and can be formed from a traditionalbi-axially stretchable material or a biaxially stretchable syntheticfibrous web material, thereby simulating conventional underwear. Thelaterally outer ends of the outer layer 162 can be attached to thelaterally outer ends of the topsheet 122 by any suitable means known inthe art, for example, via adhesive, cohesive, or the like.

Accordingly, as illustrated in FIG. 13D, the CAM or portion thereof,e.g. anchoring band 144″ can be attached to the outer cover 124laminate. In these embodiments, the LDEs 146 may be joined to theinner-facing surface of the inner layer 164 in the manner describedabove, thereby operatively coupling the core 126 to the circumferentialanchoring band 144″.

Referring now to FIG. 13E, in particular, the CAM or portion thereof,e.g. 144″, can be attached to the garment-facing surface of the topsheet122 via any suitable means known in the art, for example via adhesive,cohesive, or the like. The laterally outer ends of the CAM may be, inturn, attached to the outer cover 124 via adhesive, cohesive, or thelike 132. The LDEs 146 may be, in turn, connected to the exposedgarment-facing surface of the CAM or portion thereof, e.g. 144″, atconnection zones 148. In this illustrated embodiment, the topsheet ispreferably stretchable or elastic, and more preferably biaxiallystretchable or elastic.

In this case, the topsheet 122 can be fabricated as a biaxiallystretchable layer. The LDEs 146 can also be partly or fully attached tothe topsheet 122, or integrated into the topsheet by fabricating thetopsheet 122 with recoverable biaxial stretchability at low forceseverywhere except at the location where the topsheet 122 would overlapthe LDEs 146 if the discrete LDEs were present, as described above withreference to the outer cover 124.

It should be appreciated that the CAM need not be a discrete structure,but could instead comprise a mechanically, thermally, or chemicallytreated portion of the outer cover 124 (i.e., an integral structure) toprovide the desired structural properties described herein. For example,during the process of making a biaxially stretchable outer cover 124, aportion can be kept inextensible (e.g., where the outer cover overlapsthe CAM) as discussed with regard to FIG. 8. Alternatively, a firstportion of the CAM may be a discrete band or other separate element thatis attached to the chassis 121, while a second portion ofcircumferential anchoring member is integral with the outer cover 124 towhich the discrete band or other separate element is attached.

The LDEs 146 can be configured as described herein. For example, theLDEs 146 and/or CAM 144 may be joined to the outer cover 124 as discreteelements or may be integral with the outer cover 124 as describedpreviously.

Referring now to FIG. 14, embodiments are contemplated where anchoringbands 144′ and/or 144″ are directly joined to a core assembly. Forexample, the anchoring bands 144′ and 144″ may be joined to the coreassembly 123 without the use of LDEs. Therefore, in some embodiments,the force from the core assembly can be directly transmitted to theanchoring bands 144′ and/or 144″ via connection zones 148. Additionally,embodiments comprising waist covers as discussed heretofore may beutilized in the absorbent articles configured in accordance with FIG.14. Also, in these contemplated embodiments, the CAM 144 or portionthereof may be joined to the waist cover(s) or may be integral with thewaist cover(s).

As shown in FIG. 14, in some embodiments, one or both longitudinal endsof the core 126 can extend from the first anchoring band 144′ to thesecond anchoring band 144″ (it should further be appreciated that thecore 126 could extend beyond anchoring bands 144′ and 144″). Theanchoring bands 144′ and/or 144″ may be joined to the core 126 by anysuitable means known in the art. Some suitable examples includeadhesives, cohesives, heat seals such as ultrasonic bonds, high pressurebonds, RF (radio frequency) bonds, hot air bonds, heated point bonds,and the like as appreciated by one having ordinary skill in the art.

Referring now to FIGS. 15A-15G, the present inventors recognize that theprinciples of the present invention as described above with respect topant-like garments are equally applicable to garments, such as absorbentarticles, that are configured as taped diapers (i.e., diapers that arenot necessarily pre-closed within a package of absorbent articles).While some of the description above pertaining to pant-like garments isincluded in the description below of taped diapers for the purposes ofform and clarity, the omission of other portions above from thedescription below does not imply that those omitted portions are not, orcannot be, incorporated into a taped diaper. Rather, the omittedportions are not described below to minimize redundant descriptionthroughout this document. Accordingly, unless otherwise specified, itshould be appreciated that all features described above with respect tothe pant-like absorbent articles can also be incorporated into tapeddiapers. Furthermore, unless otherwise specified, it should beappreciated that all features described below with respect to tapeddiapers can also be incorporated into pant-like garments. For thepurposes of form and clarity, a taped absorbent article 220 isillustrated in FIG. 15A with like reference numerals corresponding tosimilar elements of FIGS. 1A-1C incremented by 200.

As shown in FIG. 15A, the absorbent article 220 has a centrallongitudinal centerline 300 and a central lateral centerline 310. Theabsorbent article 220 may include a substantially hourglass-shapedchassis 221 having a first, or front, waist region 236, a second, orback, waist region 238 opposed to the front waist region 236, and acrotch region 237 located between the front waist region 236 and theback waist region 238. The waist regions 236 and 238 generally comprisethose portions of the diaper 220 which, when the diaper 220 is worn,encircle the waist of the wearer. The waist regions 236 and 238 caninclude elastic elements such that they gather about the waist of thewearer to provide improved fit and containment. The crotch region 237 isthat portion of the diaper 220 which, when the diaper 220 is worn, isgenerally positioned between the legs of the wearer. The outer peripheryof the chassis 221 is defined by lateral end edges 256 that can beoriented generally parallel to the lateral centerline 310, and bylongitudinal side edges 254 that can be oriented generally parallel tothe longitudinal centerline 300 or, for better fit, can be curved orangled, as illustrated, to produce an “hourglass” shaped garment whenviewed in a plan view. In some embodiments, the longitudinal centerline300 may bisect the end edges 256 while the lateral centerline 310 maybisect the side edges 254.

The chassis 221 can comprise a liquid pervious topsheet 222, and aliquid impervious outer cover 224 joined to the topsheet 222 proximalthe lateral end edges 256 and the longitudinal side edges 254 via anysuitable method known in the art. Some suitable examples includeadhesives or cohesives. While adhesive or cohesive may be used toconnect various absorbent article components as illustrated anddescribed herein, one having ordinary skill in the art will appreciatethat any suitable alternative attachment mechanism can facilitate suchconnections. Examples of suitable alternatives include, but are notlimited to, thermal bonds, RF (radio frequency) bonds, pressure bonds,ultrasonic bonds, welds, stitching, and the like.

A cover 247 can be disposed about the side edges 254 that provide theperiphery of the leg openings once the diaper 220 is closed, and thusengage the wearer's legs during use. Similarly, as shown, in someembodiments, a cover may similarly be disposed about the end edges 256that provide the periphery of the waist opening once the diaper 220 isclosed, and thus engages the wearer's waist during use. In someembodiments, the cover 247 can be elastic and joined to the outer cover224 while the cover 247 is under tension such that upon relaxationgathers the side edges 254. Finished outer leg cuffs and waist edges arediscussed in U.S. Pat. No. 5,797,824 and U.S. Pat. No. 7,013,941, whilethe latter also discusses methods and an apparatus for applying thematerial.

As described above with respect to absorbent article 220, the outercover 224 can advantageously be bi-axially stretchable, therebyenhancing both the comfort of the diaper 220 on the wearer and theconformability to the wearer's anatomy during movement. In someembodiments, a substantially hourglass-shaped absorbent core assembly223 can be positioned between the topsheet 222 and the outer cover 224.In some embodiments the core assembly 223 can be configured similar tothe core assembly 23 described heretofore.

As illustrated in FIG. 15C, in some embodiments the core assembly 223can be “tacked” (either via an adhesive, cohesive, or the like) to theouter cover 224 at one or more discrete locations 225, where wearermovement is unlikely to cause the connection between the core assembly223 and the outer cover 224 to restrict outer cover stretchability.These discrete locations are also referred to herein as regions of lowmotion. Tacking the core assembly 223 in this manner would assist inpreventing substantial movement of the core assembly 223 relative to thewearer's body. One example of a location suitable to tack the coreassembly 223 to the outer cover 224 includes the crotch region 237, andparticularly proximal to the intersection of the longitudinal axis 300and the lateral axis 310. As illustrated in FIG. 15D, the remainingregions of the core assembly 223 are not required to be attached to theouter cover 224. In some embodiments, the bond area between the coreassembly 223 and the outer cover 224 can be between about 1 cm² andabout 20 cm² or any individual number within the range. In someembodiments, the core assembly 223 may be bonded to the outer cover 224wherein the bond area resemble a strip extending the substantial lengthof the core assembly 223 and being long and narrow.

Referring again to FIG. 15A, the diaper 220 can also include a waistband243 that helps provide improved fit and containment, as is appreciatedby one having ordinary skill in the art. The waistband 243 is thatportion or zone of the diaper 220, which is intended to elasticallyexpand and contract to dynamically fit the wearer's waist. The elasticwaistband 243, in some embodiments, may form at least a portion of theend edge 256 of the diaper 220. Disposable diapers can be constructed soas to have at least one elastic waistband positioned in the front waistregion 236 and/or back waist region 238. Furthermore, while in someembodiments the elastic waistband 243 or any of its constituent elementscan include a separate element affixed to the diaper 220, the waistband243 need not be separately affixed to the diaper 220, as describedheretofore. The waistband 243 may be configured as described heretofore.

The diaper 220 can include a pair of side panels 227 that extendlaterally outward from the longitudinal side edges 254 proximal thelateral end edge 256 in the back waist region 238. The side panels 227can be attached to the chassis 221 at attachment zone 245 using anyknown attachment apparatus or, alternatively, the side panels 227 can beformed integrally with the chassis 221. The side panels 227 may beelastic in some embodiments. Additionally, in some embodiments, thediaper 220 may further comprise a pair of side panels extendinglaterally outward from the longitudinal side edges 254 in the firstwaist region 236. The side panels 227 may be discrete elements which arejoined to the first waist region 236 and/or the second waist region 238.Alternatively, in some embodiments, the side panels 227 may be integralwith a portion of the diaper 220. For example, the side panels 227 maycomprise a portion of the topsheet 222, outer cover 224, and/or legcuffs.

The disposable absorbent article 220 further comprises a fasteningsystem 229 which can join at least a portion of the first waist region236 with at least a portion of a second waist region 238, preferably toform leg and waist openings. The fastening system 229 also works withthe waistband 243 to maintain lateral tension about the waist of thewearer. The fastening system 229 may comprise engaging components 231which, in some embodiments, can be disposed on the side panels 227. Thefastening system 229 may further comprise a receiving component 239which, as illustrated, is disposed in the front waist region 236. Thereceiving component 239 can be integral with the chassis 221, or can beconnected via a side panel extending outward from the chassis 221.

Any suitable engaging element 231 can be used in the present invention.An example of a suitable engaging element 231 comprises hook fasteningmaterial. The hook fastening material can mechanically engage fibrouselements of the receiving element 239 so as to provide a secure closure.A hook fastening material according to the present invention may bemanufactured from a wide range of materials. Suitable materials includenylon, polyester, polypropylene, or any combination of these materials,or other materials as are known in the art.

A suitable hook fastening material comprises a number of shaped engagingelements projecting from a backing such as the commercially availablematerial designated Scotchmate™ brand No. FJ3402 available fromMinnesota Mining and Manufacturing Company, St. Paul, Minn.Alternatively, the engaging elements may have any shape such as hooks,“T's”, mushrooms, or any other shape as are well known in the art. Anexemplary hook fastening material is described in U.S. Pat. No.4,846,815. Another suitable hook fastening material comprises an arrayof prongs formed of thermoplastic material. Hot melt adhesivethermoplastics, in particular polyester and polyamide hot meltadhesives, are particularly well suited for forming the prongs of thehook fastening material. The prongs, in some embodiments, can bemanufactured using a modified gravure printing process by printing thethermoplastic material in its molten state onto a substrate in discreteunits, severing the material in a manner that allows stretching of aportion of the thermoplastic material prior to severance, and allowingthe stretched molten material to “freeze” resulting in prongs. This hookfastening material and methods and apparatus for making such a hookfastening material are more fully detailed in European PatentApplication 0 381 087.

The fastening system 229 may be the primary fastening system for joiningthe front and back waist regions 236 and 238. However, the fasteningsystem 229 may be used alone or in conjunction with other fasteningmeans such as tab and slot fasteners, tape fasteners, snaps, buttons,and the like to provide different fastening characteristics. Forexample, the fastening system 229 may provide the disposable absorbentarticle 220 with a disposal means for fastening the disposable absorbentarticle 220 in a configuration convenient for disposal. Further,secondary fastening means may provide the disposable absorbent article220 with a means for adjusting fit or may increase the strength of theconnection between the front waist region 236 and the back waist region238.

When the diaper 220 is worn on the lower torso of a wearer, the endedges 256 encircle the waist of the wearer while, at the same time, thechassis side edges 254 define leg openings that receive the legs of thewearer. The crotch region 237 is generally positioned between the legsof the wearer, such that the absorbent core assembly 223 extends fromthe front waist region 236 through the crotch region 237 to the backwaist region 238.

It should be appreciated that the positions of the side panels 227 andthe receiving elements 239 can be reversed with respect to theembodiment illustrated in FIG. 15A, such that the side panels 227 extendfrom the longitudinal side edges 254 proximal the lateral end edge 256in the front waist region 236, while the receiving elements 239 aredisposed proximal the lateral end edge in the back waist region 238.Alternatively still, a pair of side panels 227 can be disposed in boththe front and back waist regions 236 and 238, with a pair of the sidepanels in a given waist region including a fastening member configuredto engage the opposing side panels.

The present invention recognizes that the core assembly 223 is capableof absorbing substantial loads during use, and that the fit ofconventional diapers can be worsened when the increased weight andresultant downward forces exerted on the core (and from the core toother diaper components) cause the absorbent article 220 to sag orotherwise be distended. Accordingly, referring again to FIGS. 15A-19Bthe diaper 220 includes an anchoring system 242 similar to the anchoringsystem 42 described above and illustrated with respect to absorbentarticle 20. Like anchoring system 42, the anchoring system 242 includesa circumferential anchoring member 244 (designated as 244′ in the frontwaist region and 244″ in the back waist region) that surrounds thewearer's body at the lower torso region, and a plurality of LDEs 246connected between the core assembly 223 and the circumferentialanchoring member 244. In some embodiments, the circumferential anchoringmember 244 can be disposed longitudinally inboard of the elasticwaistband 243. In some embodiments, the CAM 244 may form a portion ofthe end edge 256 of the diaper 220.

During use, when the core assembly 223 absorbs an excremental load, forexample, a gravitational and/or inertial force is applied to the coreassembly 223 which tends to push the core assembly 223 downward. Thecore assembly 223 transmits the force to the LDEs 246 which in turndistributes the force to the CAM 244. The CAM 244 in turn, transfers theforce to the wearer's body (e.g., at the lower torso region). Inembodiments comprising the BSOC, the BSOC can force-decouple a potentialpathway between the core assembly 223 and the anchoring system 242ensuring that the anchoring system 242 receives loads from the coreassembly 223 only by the LDEs 246 as opposed to receiving loads from thecore assembly 223 by both the LDEs 246 and the outer cover 224. In someembodiments, substantially all of the load from the core assembly 223may be transferred to the CAM 244 via the LDEs 246. It will be thusappreciated that the anchoring system 242 enables the taped diaper 220to achieve an enhanced, more comfortable and underwear-like fit relativeto conventional diapers.

As shown in FIG. 15A, in some embodiments, the CAM 244 may comprise afirst anchoring band segment 244′ extending between opposing side edges254 in the front waist region 236, and a second anchoring band segment244″ extending between opposing side edges 254 in the back waist region238. While segments 244′ and 244″ can assume any one of a number ofconfigurations as described heretofore with regard to the CAM and/oranchoring bands, in the illustrated embodiment, the segment 244′ and244′ are substantially straight and extend laterally across the diaper220.

As shown in FIGS. 15B and 15E, the CAM 244 can be attached to the innersurface (i.e., opposite the garment-facing surface 252) of the outercover 224 via any suitable means known in the art, for example, adhesiveor cohesive. When the fastening system 229 is closed to correspondinglyclose the taped diaper 220, the segments 244′ and 244″ are operativelyconnected to form the continuous CAM 244 that surrounds the wearer'slower torso region.

As shown in FIG. 15A, in some embodiments, the CAM 244 may comprise oneor more connection zones 248 where the LDEs 246 are joined to the CAM244. Similarly, connection zones 248 can exist where the LDEs 246 arejoined to the core assembly 223. The LDEs 246 may be configuredsimilarly to the LDEs 46 and 146.

In some embodiments, the LDEs 246 can comprise bands that arenon-stretchable so as to transfer the gravitational and/or inertiaforces at the core assembly 223 to the connection zone 248 of thecircumferential anchoring member 244. In some embodiments, the LDEs 246may comprise stretchable and/or elastic bands which transfer forces fromthe core assembly 223 to the CAM 244. For example, during loading ofcore assembly 223, if the modulus of the LDEs 246 were designed tostretch by the same amount as the added load would swell the core; thiswould prevent the anchoring system 242 from having an added load sourcefrom the core swelling.

In a particular embodiment illustrated in FIG. 15A, four LDEs 246 areconnected at one end to the four corresponding corner regions, or anyportion of the four quadrants formed by the intersection of thelongitudinal 300 and lateral 310 axes of the article, of the coreassembly 223. In the illustrated embodiment, the LDEs 246 are connectedto the outer (i.e., garment-facing) surface of the core assembly 223.Alternatively, the LDEs 246 can be connected to the inner(wearer-facing) surface of the core assembly 223. As illustrated in FIG.15A, the LDEs 246 can extend laterally outward from the core 226 andtoward the corresponding end edge 256 and terminate at opposing endsthat are connected to the outer (i.e., garment-facing) surface or theinner-facing surface of the CAM 244 at the connection zones 248. TheLDEs can be joined to the core assembly 223 and to the CAM 244 via anysuitable method known in the art, for example, any suitable adhesive,cohesive, or the like. Similar to the embodiment discussed with regardto FIG. 6, embodiments are contemplated where the connection zones 248may comprise a discrete intermediate material which can benon-stretchable, stretchable, or elastic, in order to allow the CAM 244to receive the forces from the core assembly 223 while preventing thecore assembly 223 from sagging away from the wearer's body during use.

The outer cover 224 represents a potential force transmission pathbetween the core assembly 223 and the anchoring system 242, a forcetransmission path between the core assembly 223 and the leg perimeters,and a force transmission path between the anchoring system 242 and thewaist perimeter. For enhanced operation of the anchoring system 242, itmay be desirable to force decouple the above mentioned transmissionpaths utilizing a suitable outer cover 224. For example, a suitableouter cover 224 as previously discussed, is a BSOC.

As shown in FIG. 15F, in some embodiments, the first anchoring bandsegment 244′ can overlap a portion of the second anchoring segment band244″. The receiving component 239 is joined to 244′ which has distaledge 244A and a proximal edge 244B. In a fastened state, the engagingcomponent 231 engages the receiving component 239.

In order for the LDEs 246A and 246B to be properly coupled into the CAM244, the overlap between the anchoring bands 244′ and 244″ should bedisposed between the connection zones 248 of the LDE 246A and theconnection zone 248 of the LDE 246B. Additionally, in order for the LDEs246A and 246B to be properly coupled into the CAM 244, the engagingcomponent 231 should be disposed between the connection zones 248 of theLDE 246A and the connection zone 248 of the LDE 246B. For example, asshown, the engaging component 231 can engage the receiving component 239adjacent to the distal edge 244A of the receiving component 239. Thispositioning represents the largest circumference possible in the CAM244, when a corresponding engaging element is similarly affixed on theopposite side of the article.

In contrast, as shown in FIG. 15G, the engaging element 231 is disposedproximate to the connection zone 248 of the LDE 246B. This embodimentrepresents a larger configuration for the positioning of the engagementelement 231 with respect to the connection zone 248 of the LDE 246B.Additionally, this positioning represents a smaller circumference of theCAM 244, when a corresponding engaging element is similarly affixed onthe opposite side of the article.

Referring now to FIG. 16, one alternative embodiment of the presentinvention recognizes that the LDEs 246 can be integrally connected tothe circumferential anchoring member 244. For example, as shown, atleast one of the LDEs 246 is integral with its corresponding anchoringband 244′ and/or 244″.

In some embodiments, as illustrated in FIG. 17, the LDEs 246 can beintegrally connected via a spine 251 that extends longitudinally alongthe core assembly 223. In particular, at least a portion of, the spine251 may be connected to the outer (garment-facing) surface of the coreassembly 223 via an adhesive, cohesive, or suitable alternative and/orequivalent. In some embodiments, the spine 251 can be laterallycentrally disposed on the core assembly 223, and can extend between thelongitudinal outer edges of the core assembly 223. As illustrated, insome embodiments, the spine 251 terminates at both longitudinal endsshort of the longitudinal end of the core assembly 223. The LDEs 246 mayextend longitudinally and laterally outboard of the spine 251.Alternatively, in some embodiments, the spine 251 and LDEs 246 can beintegrally connected to the circumferential anchoring band segments 244′and 244″ as illustrated in FIG. 18.

The spine 251 can provide structural support for the core assembly 223.For example, conventional cores made up of airfelt may benefit from theincorporation of the spine 251.

As shown in FIG. 17, in some embodiments, the LDEs 246 may be discretelyjoined to the spine 251 and to the anchoring band segments 244′ and/or244″. Alternatively, in some embodiments, the LDEs 246 may be integralwith the spine 251 and discretely joined to the anchoring band 244′and/or 244″. In still other embodiments, the LDEs 246 may be integralwith the anchoring band 244′ and/or 244″ and discretely joined to thespine 251. In some embodiments, such as the embodiment of FIG. 18, theanchoring bands 244′ and 244″ and the LDEs 246 and the spine 251 can allbe integral with each other. It should be appreciated that the spine 251can be formed from the same material as LDEs 46, 146, and 246 or, ifLDEs 246 are discretely connected to the spine 251, the spine can beformed from any suitable alternative material appreciated by one havingordinary skill in the art, including a portion of the outer coversubjected to less incremental stretching than the surrounding regions ofthe outer cover, as discussed heretofore.

Referring to FIGS. 19A and 19B, an absorbent article 320 is illustratedhaving reference numerals corresponding to like elements of FIGS. 1A-1Cincremented by 300 for the purposes of clarity and convenience. Theabsorbent article 320 can include a pair of stretchable (e.g., in themachine cross direction) ears 317 (also referred to as an elasticallystretchable side panel) that are attached (e.g., via mechanical,pressure, or ultrasonic bonding and/or glue etc.) to a chassis 321. Theears are thus stretchable in a direction substantially parallel to thelateral centerline 410.

Such stretchable ears are 317 are described, e.g., in U.S. Pat. No.5,674,216. Typically they consist of a laminate of an (breathable)elastomeric film sandwiched (preferably with glue) between two layers of(preferably activatable) nonwoven such as DAPP or HEC. After laminationthe ears 317 are activated, i.e., via ring rolling, as e.g. described inU.S. Pat. No. 5,156,793 or in U.S. Pat. No. 5,167,897 to allow the earsto stretch in the cross direction.

Hooks 319 (and associated stiffener element, if desired) may be appliedto the ear during the process of manufacturing the article or when theear laminate is produced. Suitable hooks 319 are available from AplixCorporation as 963 hooks. Additionally, any hooks discussed heretoforemay be utilized.

The ears 317 can be attached to an activatable auxiliary nonwoven 315such as a DAPP or HEC. An example of a suitable DAPP nonwoven isavailable under the designation Softspan 200 by BBA Fiberweb, Brentwood,Tenn.

An auxiliary nonwoven layer 315 can join the absorbent assembly 323 andthe ears 317 as shown in FIG. 19B. The auxiliary nonwoven may be foldedover to encapsulate the outer leg elastics 363. In this embodiment, theauxiliary nonwoven 315 forms the front ear 313, the area to attach toback ears 317, and the material that encapsulates the curved outerelastics 363.

After the (curved) outer elastics 363 are attached to the biaxiallystretchable outer cover 324 material and the auxiliary nonwoven 315 isfolded over and (glue) bonded to the biaxially stretchable outer cover324, the chassis 321 is selectively activated as e.g. described in U.S.Pat. No. 6,383,431 (Dobrin et al) in the machine direction and in thecross direction. The core assembly 323 can be tacked, if desired, to theouter cover 324 at location 339. An example of a suitable outer legelastic 363 is available under the designation item#17087 available fromFulflex.

As seen in the drawing, some regions of the chassis 321 are notactivated. These regions will form the chassis part of the anchoringsystem 342. The drawing clearly shows the circumferential anchoringmember 344 and the load distribution elements 346 intended to link thecore assembly 323 to the circumferential anchoring member 344. Theseregions are subjected to substantially less incremental stretching thenthe other regions of the outer cover. As can be seen in this executionthe anchoring system 342 is made of the same structure as the wholechassis 321 via selective activation and is an intimate part of theouter cover 324.

In certain embodiments, the circumferential anchoring member 344exhibits minimal strain under applied tension. An exemplarycircumferential anchoring member 344 stretches only by 2% under a loadof 0.9 N/cm.

If the unactivated biaxially stretchable outer cover material is, in itsbasic state, insufficiently resistant to extension, the strength of thecircumferential anchoring member 344 may be increased via over-bondingthe material. Over-bonding works especially well for nonwovens, but alsoworks for laminates. Over-bonding, in essence, involves the applicationof heat and pressure to selected areas of the biaxially stretchableouter cover material, thereby melting part of the material and creatingadditional bond sites, or even film like structures (rather than thenonwoven structures).

It may be desirable to not activate the distal edges (the areas of theauxiliary nonwoven 315 that extend beyond the biaxially stretchableouter cover 324) of the auxiliary nonwoven 315. If said distal edges arenot activated the web maintains a portion that has a relatively highmodulus. This can be advantageous for web handling during the process ofmanufacturing the absorbent article.

When activating the chassis 321, care should be taken to not to createtoo much fuzz (i.e., dust, lint, loose fibers/material), createpin-holes, or damage the outer elastics, while achieving the desiredlevel of lateral and longitudinal extensibility.

Fuzz creation is undesirable for line hygiene reasons and becauseconsumers associate low fuzz levels with durability. With respect to thecreation of fuzz, it has been found that it is desirable to create lessthan 0.12 mg/cm² of fuzz. A suitable fuzz test method is disclosed inU.S. Pat. No. 5,433,826.

Fuzz creation can be minimized by selection of appropriate nonwovens,the right activation process settings (lower strain rates, less depth ofengagement are preferred), and the way how the auxiliary nonwoven iscombined/bonded with the biaxially stretchable outer cover. In certainembodiments, it is preferable that the bonding between the auxiliarynonwoven 315 and the biaxially stretchable outer cover is not toointimate. For example, spiral glue has been found to be an acceptablemethod of bonding. In addition it has been found that it is desirable toactivate the chassis 321 while the (spiral) glue combining the auxiliarynonwoven with the biaxially stretchable outer cover is still hot tominimize fuzz and pinhole generation.

While in this execution the chassis 321 does not need to be liquidimpermeable, it still has been found that it is desirable to have as fewpin-holes as possible. One reason is that the absence of pinholes is asignal of quality to the consumer as well as a re-assurance that theproduct will not leak. In light of this it has been found that it isdesirable to have less than 0.1 pinholes per linear meter of chassis. Inbroad terms, a pinhole is a part of the chassis 321 stretched to 10% inmachine direction and to 10% in cross direction were the opacity is atleast 10 units lower than the average, and the pinhole area is largerthan 0.5 mm².

It has been found that in general the same considerations that reducefuzz also reduce pin-holes. Beyond the considerations identical to thefuzz generation it has been found that if the biaxially stretchableouter cover has a layer that is the main contributor of the opacity ofthe biaxially stretchable outer cover (like a film or a layer of meltblown or nano fibers), then it is desirable that this layer have elasticproperties.

One way of avoiding the destruction of elastics is to avoid activatingin the areas in which the outer elastics are disposed. Another way is todecrease the depth of engagement in the areas containing the outerelastics.

If desired, a preferably chevron shape landing zone 339 may be attached(glued) to the biaxially stretchable outer cover. An example of asuitable landing zone is sold under the designation NALT 27 chevronshaped landing zone produced by Aplix.

In some embodiments, biaxially stretchable outer cover 324 materialsprovide enough loops of fibers on the outside, such that the hooks 319can engage with the biaxially stretchable outer cover 324 without theneed of an additional landing zone 339. For example, a biaxiallystretchable outer cover 324 may comprise an SMS nonwoven that isactivated in the region typically occupied by a landing zone andsubsequently over-bonded to create sufficient strength in the lateraldirection to form an integral landing zone from the outer covermaterial. In other embodiments, the landing zone can be extensible inboth the longitudinal and lateral directions and may be glued to thecenter chassis prior to or after activation.

A contractible finished waistband (not shown in this figure) may beapplied to the inside, outside, or both, of the center chassis. Anysuitable waistband known in the art may be utilized.

After the chassis 321 is activated a self-contained (or “bucket”) coreassembly 323, such as that depicted in FIGS. 1A-1C, may be attached tothe chassis 321 by attaching the core to the LDE(s) 346, the CAM(s) 344,and/or directly to the outer cover 324. FIG. 19A shows regions 332 wherethe core assembly 323 is preferably attached to the chassis 321 andadditional regions 311 where the core assembly 323 may be attached tothe chassis 321 in certain embodiments. While the drawing shows theattachment sites 332 as squares, the attachment regions may comprise anysuitable shape. When attaching the core assembly 323 to the chassis 321,the desire to bond as little area as possible to allow the chassis 321to stretch and conform to the wearers body as much as possible isbalanced with the desire to bond as much as possible, so that the coreassembly 323 does not easily separate from the rest of the absorbentarticle 320.

One preferred way of attaching the core assembly 323 to the chassis 321is to sandwich the core assembly 323 in the front and back regions 336and 338 between the center chassis 321 and an optional waist cover 307.This way the core assembly 323 can not flip over, but by making thewaist cover 307 extensible at least in the machine direction the abilityof the center chassis 321 to stretch and conform to the wearer's body isless restricted than by gluing the core assembly 323 to the centerchassis 321.

The waist cover 307 can be configured as discussed heretofore withregard to the waist cover 1523 (shown in FIGS. 11 and 12A).Additionally, in some embodiments, the CAM 344 and/or LDEs 346 can beattached to the waist cover 307 instead of the outer cover 324, thussignificantly improving outer cover 324 aesthetics and productconformity, especially in the longitudinal direction. In someembodiments, the CAM 344 and/or the LDEs 346, or a portion thereof, canbe integral with the waist cover 307. For example, portions of the waistcover 307 which are not the CAM 344 and/or the LDEs 346 may beincrementally stretched more so than the CAM 344 and/or the LDEs 346.

After the core assembly 323 has been attached to the chassis 321, theback ear 317 may be attached and the side notch may be cut out. Afterthis the diaper 320 may be cut, folded, and put into bags.

The advantage of making the diaper 320 this way is that by assemblingthe absorbent article in the described sequence, there is always a partof the web that has a relatively high elastic modulus, providing easierweb handling at high line speeds.

While a rectangular shaped core assembly 323 is relatively easy tofabricate, it can be desirable for the absorbent materials containedinside the core assembly 323 (e.g., nonwoven acquisition layers, fibrousacquisition layers, cellulose fibers, superabsorbent polymers, nonwovenforming or containment layers, etc.) to be shaped. Shaped absorbentmaterials conform much better to the wearer's anatomy; give theimpression of less bulk between the legs and the impression of a betterfitting product.

Specifically it has been found that it is desirable that the width ofthe absorbent materials in the region of the wearer crotch. i.e., thewidth of the core assembly in the crotch region is no greater than about50 mm wide (independent of the age of the wearer). Alternatively, thewidth of the core in the crotch region may be up to about 70 mm, or evenabout 90 mm, in come embodiments.

An additional advantage of a relatively narrow core assembly in thecrotch region 337 is that the effective cuff height of the barrier legcuffs is increased.

Similarly, it has been found that it is desirable for the absorbentmaterials to be as wide as 110 mm, or even 130 mm in the front region336 and in the back region 338 (for babies). For adults it may bedesirable to spread the absorbent materials in the front and in the backeven further.

The illustrated embodiment can be made from the following materials inaccordance with one aspect of the invention.

Variations to the embodiment illustrated in FIGS. 19A-19B could beimplemented. For instance, the bucket core assembly 323 could bediscrete (i.e., not run the full length of the chassis 321).Furthermore, the biaxially stretchable outer cover 324 could be foldedover and replace the auxiliary nonwoven. Additionally, rather thanattaching the stretch back ears 313, the biaxially stretchable outercover 324 could extend the full width of the article and comprisestretch elements. Finally, rather than making the anchoring system 342out of the biaxially stretchable outer cover 324 via selectiveactivation one could add an anchoring system made of a nonwoven or of anelastomeric film/nonwoven laminate attached separately to the coreassembly as described herein.

FIG. 20A illustrates a plan view of an embodiment of disposableabsorbent article 2000-A with side fasteners 2003 and an anchoringsystem 2021. The anchoring system 2021 includes a CAM 2007 and LDEs2005. The anchoring system 2021 includes stretchable portions 2051including stretchable CAM portions 2007-S, disposed laterally outboardof intersections between the CAM 2007 and the LDEs 2005.

FIG. 20B illustrates a plan view of an embodiment of disposableabsorbent article 2000-B with side fasteners 2003 and an anchoringsystem 2022. The anchoring system 2022 includes a CAM 2007 and LDEs2005. The anchoring system 2022 includes stretchable portions 2052including stretchable CAM portions 2007-S and stretchable LDE portions2005-S, disposed through intersections between the CAM 2007 and the LDEs2005.

FIG. 20C illustrates a plan view of an embodiment of disposableabsorbent article 2000-C with side fasteners 2003 and an anchoringsystem 2023. The anchoring system 2023 includes a CAM 2007 and LDEs2005. The anchoring system 2023 includes stretchable portions 2053including stretchable CAM portions 2007-S, disposed laterally outboardof intersections between the CAM 2007 and the LDEs 2005.

Test Methods

Hysteresis Test for Elastic Properties

(i) Sample Preparation for the Elastomeric Material

Samples dimensions are as described below.

BSOC—(1″ width by 3″ length)

Topsheet (1″ width by 3″ length)

CAM—(width of the CAM generally parallel to the longitudinal axis of thediaper by 3″)

LDE—(width of the LDE by 3″)

Hysteresis Test for the Elastomeric Composite

A commercial tensile tester from Instron Engineering Corp., Canton,Mass. or SINTECH-MTS Systems Corporation, Eden Prairie, Minn. (or acomparable tensile tester) is used for this test. The instrument isinterfaced with a computer for controlling the test speed and other testparameters, and for collecting, calculating and reporting the data. Thehysteresis is measured under typical laboratory conditions (i.e., roomtemperature of about 20° C. and relative humidity of about 50%).

The procedure for determining hysteresis involves the following steps:

-   -   1. choose the appropriate jaws and load cell for the test; the        jaws are wide enough to fit the sample, typically 1″ wide jaws        are used; the load cell is chosen so that the tensile response        from the sample tested will be between 25% and 75% of the        capacity of the load cells or the load range used, typically a        50 lb load cell is used;    -   2. calibrate the tester according to the manufacturer's        instructions;    -   3. set the gauge length at 25 mm;    -   4. place the sample in the flat surface of the jaws such that        the longitudinal axis of the sample is substantially parallel to        the gauge length direction;    -   5. the hysteresis test involves the following steps:    -   a) pull the sample to 50% strain at a cross head speed of 10        in./min (254 mm/min)—first cycle loading    -   b) hold at that strain for 30 seconds and return to 0% strain at        the same crosshead speed—first cycle unloading    -   c) allow the sample to remain at this strain for 1 minute; and    -   d) pull to 50% strain at a constant rate of 10″/min (254        mm/min)—second cycle load    -   e) hold at that strain for 30 seconds and return to 0% strain at        the same crosshead speed—second cycle unloading

From the data collected in step 5, the following two measurements areused:

-   -   a) first cycle force at 15% strain    -   b) % set, which is defined as the strain at 0.05N in the second        loading cycle. The 0.05N force is deemed sufficient to remove        the slack but low enough to impart, at most, insubstantial        stretch to the sample.    -   6. Record data for first cycle load at 15% strain    -   7. Record data for % set.        Air Permeability

Air permeability is determined by measuring the time in which a standardvolume of air is drawn through a test specimen of a defined area at aconstant pressure and temperature. This test is particularly suited tomaterials having relatively high permeability to gases, such asnonwovens, apertured films and the like. The air permeability test isperformed according to ASTM D737-96 entitled “Standard Test Method forAir Permeability of Textile Fabrics” with the following test parameters.A TexTest FX3300 instrument is used. (Available by Textest AG inSwitzerland (www.textest.ch), or from Advanced Testing Instruments inSpartanburg S.C., USA.) The test is conducted in a laboratoryenvironment at about 22±2° C. and about 50% relative humidity. The testpressure drop is 125 Pascal and the test area is 38 cm². In this test,the instrument creates a constant differential pressure across thesample which draws air through the sample. The rate of air flow throughthe sample is measured in ft³/ft²/min (often called cfm or ft/min) orm³/m²/min (or m/min). For each sample, three replicates should be run,and the average result is reported.

Hydrostatic Head (Hydrohead) Pressure

The property determined by this test is a measure of the liquid barrierproperty (or liquid impermeability) of a material. Specifically, thistest measures the hydrostatic pressure the material will support: when acontrolled level of water penetration occurs. The hydrohead test isperformed according to EDANA 120.2-02 entitled “Repellency: HydrostaticHead” with the following test parameters. A TexTest Hydrostatic HeadTester FX3000 (available from Advanced Testing Instruments, Corp.,Spartanburg, S.C., or by Textest AG in Switzerland (www.textest.ch)) isused. For this test, pressure is applied to a defined sample portion andgradually increases until water penetrates through the sample. The testis conducted in a laboratory environment at about 22±2° C. temperatureand about 50% relative humidity. The sample is clamped over the top ofthe column fixture, using an appropriate gasketing material (o-ringstyle) to prevent side leakage during testing. The area of water contactwith the sample is equal to the cross sectional area of the watercolumn, which equals 28 cm². Water is pumped into the water column at arate of 20 mbar/min. Thus, the sample is subjected to a steadilyincreasing water pressure on one surface. When water penetration appearsin three locations on the other surface of the sample, the pressure(measured in mbar) at which the third penetration occurs is recorded. Ifwater immediately penetrates the sample (i.e., the sample provided noresistance), a zero reading is recorded. For each material, threespecimens are tested and the average result is reported.

In various embodiments of the present disclosure, an absorbent articlewith an anchoring system can have a backsheet, an absorbent core and atopsheet, provided with at least one opening adapted to receive fecalmaterial, said topsheet and said opening thereof each having a frontregion and a back region, characterized in that said diaper comprises agenital coversheet, which in use covers the genitals, and which ispositioned in, under or above said front region of the opening, wherebya void space is formable between the genital coversheet and theabsorbent core, and whereby a void space is present between the topsheetand the absorbent core. Thus, the genital coversheet reduces the size ofthe opening.

Such a genital coversheet is typically urine permeable, so that theurine can pass through it immediately to the absorbent core of thediaper, and it preferably has a low rewet, so that the amount of urinepassing back to the genitals is minimized. In another embodiment, anabsorbent article, typically an adult or infant diaper or training pantscomprising a backsheet, includes an absorbent core and a topsheet, andintegral therewith a genital cover portion, said topsheet having a frontregion and a back region, and said topsheet comprising in part of saidfront region and part of said back region back region an opening,preferably a single opening, to receive fecal material, characterized inthat said topsheet comprises in the front region a genital cover portionthat is urine permeable (and that preferably can form a pocket and/orhas the extendibility described herein for the genital coversheet) andthat the topsheet comprises in the back region an urine-impermeable andfeces-impermeable feces-retaining portion, having a mean pore size ofless than 20 microns and a air-permeability of at least 3 Darcy, wherebythere is a void space between the genital-cover portion of the topsheetand the absorbent core and between the feces-retaining portion of thetopsheet and the absorbent core.

In various embodiments, an absorbent article with an anchoring system ofthe present disclosure can also be configured as described in U.S. Pat.No. 6,482,191, which is hereby incorporated by reference.

Theory of Anchoring:

Those skilled in the art of absorbent articles will appreciate that thesize and shape of the wearer has a substantial impact on the comfort andperformance of an article in use. Absorbent articles are typically sizedto fit a given segment of the human population and a range of sizes isoffered to cover each target market for the product (such as infants,toddlers, small children or adults). Each size is intended to providecomfort and performance for all the wearers in the segment it isdesigned to fit. Anchoring is particularly sensitive to the shape andsize of the wearer.

The present invention provides anchoring systems that are more robustacross a size segment than the present art. Nevertheless, absorbentarticles have many design tradeoffs and interactions which often lead tounintended and unexpected results from seemingly innocuous changes to aproduct design. While not wishing to be bound by theory, the inventorsoffer a theory herein to explain the principles behind various aspectsof the present invention.

To help with description of locations on the wearer's body, a coordinatesystem for the wearer is defined. Detailed numerical coordinates neednot be used in this disclosure, but the coordinate axes will provide theability to qualitatively discuss relative locations. It is convenient touse the pelvis to base a coordinate system because the anchoring systemsdescribed herein are intended to remain in a fixed position about thepelvis. Note that the waist and leg perimeters of the diaper willcontact surfaces of the body which are driven by the spine and legs andcan move relative to the pelvis. Thus the body surfaces surrounding thespine and legs move and deform somewhat independently of the surfacesurrounding the pelvis. Thus during wear, the diaper perimeters at thewaist and legs may move relative to the anchoring system of the presentinvention.

Referring to FIG. 21, the coordinate system is established relative tothe pelvis as it is positioned in a baby standing upright. A baby isused as an exemplary wearer but the principles illustrated and describedherein apply to all human wearers. The origin of the coordinate systemis the center of gravity of the pelvis. The “y” axis is vertical (inline with gravity) with the positive direction pointing up. The “x” axisis oriented in the wearer's left-to-right direction with positivedirection pointing to the wearer's left (thus when viewing the wearerfrom the front, positive “x” is toward the right). The “z” axis is inthe front-to-back direction with the positive direction toward thefront.

Unless stated otherwise, the wearer is assumed to be standing in thefollowing description of the theory. It is also assumed that wearablearticles are held in place on the body by the physics of mechanicalcontact. This limits the possible interactions between the wearer's bodyand the article to normal force and friction. The present invention isfully compatible with any method to favorably enhance the interaction incontact areas such as body adhesives and the like, but these are ignoredduring the discussion of theory.

From the moment a diaper is put on a body, various forces arise withinthe diaper and between the diaper and body. These forces come from manysources such as the initial taping forces, diaper mass, body movement,urination, bowel movements, and physical interaction with clothes andparents. The weight of an absorbent article can generate significantforce in the negative y direction (downward) as it collects and storesbodily wastes. For example, a diaper designed for a toddler may weigh 50grams initially when dry and typically 100 to 200 grams when changed. Ifthe toddler were standing, this load force would tend to drag the diaperdown the body unless there was an equal upward support reaction imposedon the diaper. Another important load force comes from deceleration thatoccurs from the impact of the feet hitting the floor when the toddlerruns or jumps. The deceleration of the body would tend to drag thediaper down the body unless there was an equal upward support reactiongenerated on the diaper which decelerates at the same rate that the bodydecelerates so that the diaper will not move down the body. These twoload forces are the target loads for the anchoring system of the presentinvention.

Load forces originating from the weight of the absorbent articletypically originate in the lower half of the article; however, locationson the body that can successfully create support reactions (i.e., cansupport the load forces) are typically engaged by the upper half of thearticle. It therefore follows that a system designed to anchor thearticle may have to perform various functions such as, for example: 1)collecting load forces, 2) transmitting the load forces to parts of thebody surface favorable for creating support reactions, and 3) arrangingthe load forces so that sufficient support reactions are generated.

One feature that distinguishes the various aspects of the presentinvention from the prior art is that these functions are carried out byan anchoring system made up of a network of anchoring bands and loaddistribution elements. Another feature includes the reduction of loadstresses on other parts of the article. For example, the inclusion of aBSOC may reduce the tendency for the wearer's movement to also inducemovement in the waist and leg perimeters of the article. Additionally,by reducing force transmission from the core assembly through the outercover, the materials selected for the outer cover may includeelastic/extensible materials which can provide an underwear like lookand feel to the article while also delivering comfort and fit to thewearer.

Further, these networks can direct the load forces to the most desirableareas of the body for support in the most desirable directions that alltogether provide the needed support at the lowest tension and thereforemaximum comfort.

Regarding the first role of the anchoring system, the theory assumesthat the load forces are already collected and presented to theanchoring system as point sources. For those embodiments that have acore assembly such as 23 in FIG. 1A, there is sufficient structuralsupport for the absorbent core so that the load forces arising from thedistributed mass of the core and its contents can be “collected” to afew attachment points on the assembly. These attachments points can bedesigned to withstand the rigors that concentrated loads place on them.Those skilled in the art would recognize that other core structures mayinclude a functionally equivalent structure to the containment member 28in FIG. 1B to serve to collect the load forces so that attachments fortransmitting the loads to the anchoring system will not destroy theattachment or core integrity during wear.

Regarding the second role, the transmission of load forces can bemodeled in theory by abstract curved lines with no weight, width,thickness, or bending stiffness but possessing the axial properties ofan ideal spring thus the ability to carry loads in tension. Thesetheoretical “springs” are termed “load bands” or “force bands” herein.Loads are transmitted by load bands to those areas of the body that aresuitable for creating support reactions. A load band has a length, aspring constant, and a connection point at each end. Connection pointsare endpoints of the load band which can be connected to other loadbands or a load. Loads and other load bands that meet at a givenconnection point are free to rotate about the connection point withoutresistance in any direction except for the barrier imposed by the bodysurface.

Regarding the third role, anchoring can be described in terms of a loadforce inducing an opposing support reaction. Therefore areas of contactbetween the body and the anchoring system where the load forces andopposing support reactions meet are termed anchoring zones. The theoryconsiders three different modes in which the body can generate supportreactions in response to a load force in the anchoring zones. Each modehas a different relationship between the direction of the load force andthe direction of support reaction. To some degree the three modes arecomplimentary, which in a properly engineered anchoring system, createsa more robust system than reliance on a single mode. The modes aretermed “frictional”, “geodesic”, and “geometric”. All three anchoringmodes depend, at least in part, on the generation of a normal force whenflexible materials are wrapped in tension on a curved surface. Geometricanchoring additionally uses stored elastic energy to create supportforces.

In general, solid bodies that contact each other interact only by normalforce and friction. A normal force is one that is directed perpendicularto the surface of contact. Friction is a force generated parallel to thesurface of contact in response to a sliding force between the bodies.Friction requires normal force in order to operate. Thus a normal forceis required for any type of support interaction in the anchoring zone.Since an anchoring zone is a contact zone, the load force transmitted tothe anchoring band arrives at the anchoring zone parallel (tangential)to the surface of contact. A normal force forms in this anchoring zoneif the surface of contact has a convex curvature in the axial directionof the anchoring band.

FIG. 36 shows an element of an anchoring band in an anchoring zone. Theanchoring zone is depicted as a layer of diaper material 3602 tensionedover a curved element of the body. Only an outside layer of skin 3603 isrepresented. As shown in FIG. 36, the anchoring zone is the surfaceinterface between the layer of diaper material and outside layer ofskin. The band is tensioned along an axis indicated by T₁ and T₂. Thetension and curvature cause a normal force/unit area, F, to form atevery point there is tension and curvature. The body-side surface of theanchoring zone responds to F with a support reaction, R_(N), of equalmagnitude, which is also normal 3601 to the surface, but in the oppositedirection. For clarity, the forces are shown only at point P₀, butintegrating the force per unit area across the area will give a totalnormal force on the surface element. The normal force at a given pointis proportional to the curvature of the surface and proportional to thetension in the band at that point.

The principles of geodesic and geometric anchoring are more easilydescribed in the absence of friction, so with regard to the discussionpertaining to geodesic and geometric anchoring, an assumption is madethat frictional forces are zero.

As stated previously, in theory, a force band may act as an idealspring. When stretched across a curved surface between two points, theforce band will seek a path that minimizes its potential energy. Thepotential energy of a spring being proportional to its stretched length,a stretched force band takes an equilibrium path that is the shortestpath between the two points. The shortest path between two points on acurved surface is mathematically defined as a “geodesic”. The geodesicformed between two points is called an “open” geodesic.

Some of the relevant properties of geodesics as defined by generallyaccepted mathematics will be used herein to describe the application ofgeodesic principles to the anchoring systems of the present invention.More information on geodesics and their mathematical properties can befound in texts on differential geometry and the theory of generalrelativity, for example, Barrett O'Neill, Elementary DifferentialGeometry Ch. 7 (Academic Press 2006); and James Foster & David J.Nightingale, A Short Course in General Relativity Ch. 2.1 (SpringerScience and Business Media 2006).

On a convex, frictionless surface, a force band in tension will follow ageodesic path. The two points that define the force band are termed“endpoints”. If the region between two endpoints on a surface contains aconcave area, a force band under tension can bridge the concave area.The portions of the path that the force band contacts will be geodesics,and the portions of the force band spanning the contacted portions ofthe path will also be a geodesic because it is a straight line in space.In contrast, a mathematical geodesic would be forced to follow theconcave surface and would not be able to bridge (span) the concavesurface. Thus a mathematical geodesic would have a longer path than theforce band where the shortest distance between the two endpointsincluded a concave surface. Although they are used in a similar fashionhere, a geodesic is a geometric concept that has no means to carrytension; and a force band does. This explains why a force band bridges aconcave region of a surface and a geodesic doesn't.

Force bands have some very useful properties for constructing anchoringsystems because they follow geodesic surface pathways and because theycarry tension. These properties have a direct bearing on how theanchoring system works. In the following discussion the surface isassumed to be a convex curved surface. In general what applies to amathematical geodesic on a convex surface also applies to a force bandon a surface with concave regions. Key aspects of mathematical geodesicsas they relate to anchoring systems include:

-   1. The mathematical definition of a geodesic allows one to extend a    geodesic beyond the two points that originally defined it, i.e.,    mathematically, a geodesic has no end other than where it intersects    the edge of a bounded surface. For many closed surfaces, the    extended geodesic may intersect itself forming a closed geodesic.    FIGS. 22 and 23 show force bands on open and closed geodesics,    respectively.-   2. A closed geodesic may form an angle, y, where it intersects    itself (called a “corner”). Note that geometrically, only the    circumferential path turns the corner. Both ends of the geodesic    path theoretically continue straight through the corner and follow    the mathematic definition of a geodesic as long as there is surface.    In schematic anchoring systems, force bands typically end at the    corner and the geodesic extensions are truncated and replaced by a    single vector representing a load force. The corner itself is    considered a connection point 548 where a load force or another    force band can be attached (shown in FIG. 23).-   3. A force band under tension following a closed geodesic, but with    no load connections may form a continuous smooth curve with no    corner (therefore γ=π radians). This condition is a shortest closed    path. A closed geodesic with a corner has a longer path compared to    a closed geodesic that passes through the corner at γ=π.-   4. Another consequence of the mathematical definition of geodesics    is that the only force a tensioned force band places on a    frictionless surface is normal to the surface. For this reason    anchoring by normal force is termed the “geodesic anchoring mode”.-   5. The geodesic path does not depend on tension, i.e., increasing    the tension of a force band has no tendency to change or “straighten    the path. In this sense, the geodesic on a curved surface is an    exact analog of a straight line in Euclidean space.-   6. In the absence of friction, force bands may arrange themselves so    they are loaded tangent to the endpoints. This is also termed    “axial” loading. If the direction of a load placed on one endpoint    changes, that endpoint will move until a new path is established    tangent to the new loading direction (in the absence of friction).-   7. All straight lines in a plane are geodesics. In FIGS. 37-39,    force bands are conveniently drawn as straight lines and the surface    is planar. However, the following statements that refer to straight    lines on a plane also hold for force bands on a curved surface.-   8. A load attached to a force band in between endpoints at any angle    other than 0 degrees or 180 degrees (i.e. tangential, in line with    the axis) causes a new geodesic endpoint to form. Referring to FIG.    37, a force band is formed by points 1 and 2 that are fixed to a    surface (endpoints are shown as circles). A load is attached to the    force band at point 3 thereby forcing the force band off its    geodesic path and creating a corner. The corner is regarded as a    connection point dividing the force band's original geodesic path    into two new ones and creating a force equilibrium with the load    force. The two force bands formed between points 1 and 3 and between    3 and 2 lengthen until the magnitude of their vector sum is equal to    the load. If the surface is curved, the vector directions would be    tangent to the geodesics. The geometry will adjust until each force    band is loaded axially. A corollary to this is that two force bands    connected to each other at their endpoints will form a single new    force band following the geodesic path between the unconnected    endpoints. Note: endpoints and connection points are essentially the    same thing except that “connection point” emphasizes that force is    being transmitted between force bands.-   9. Referring to FIG. 38, when two point loads are added to a force    band, the original force band can be broken into 3 geodesics. In    order for the forces to balance around the connection point, the    length (and therefore the tension) of all 3 force bands increases.-   10. Referring to FIG. 39, if instead of point load connections, the    load was distributed continuously along a portion of the force band,    the original force band can be broken into 2 geodesic segments and a    non-geodesic segment. The load is distributed continuously between    points 3 and 4. Segments between points 1 and 3 and between 4 and 2    follow geodesics. The segment between points 3 and 4 is a    non-geodesic force band that has been pulled away from the surface    geodesic between point 3 and 4 (represented by the thin straight    dashed line connecting them). FIG. 40 shows what happens in an    element of the anchoring zone, assuming there is contact and    curvature. FIG. 40 shows an element of an anchoring band in an    anchoring zone. The anchoring zone is depicted as a layer of diaper    material 4002 tensioned over a curved element of the body. Only an    outside layer of skin 4003 is represented. The effect of a    distributed load, L, is to shift the force, F, created on the    surface away from the normal 4001. F therefore has a normal    component, F_(N), and a tangential component, F_(T), along the    surface perpendicular to the axis of the tension in the segment    (between T₁ and T₂). In other words, when a distributed load pulls a    force band off of its geodesic, the original normal force becomes    tilted and the article side of the element gains a tangential    component to counter the load. This tangential force is termed the    “geometric anchoring force”. The geometric anchoring force comes    from stored elastic energy created as the load pulls the force band    off a geodesic path. Note that the geometric anchoring force does    not come from the body. In fact, the load force for this portion of    the load is transmitted to another site in the anchoring system    where geodesic anchoring occurs and a normal support reaction is    generated. Thus “geometric anchoring” is actually a means to    redirect loads to a location more suitable for geodesic anchoring.

The force bands described above can be configured into geodesic networksthat can be tailored for specific applications. These networks may berepresented as anchoring “schematics” that indicate the configuration ofelements of the network. Each element in an anchoring schematicindicates the function that is to be carried out by an analogous elementin the physical anchoring system. As used herein, anchoring schematicsare shown in a perspective view on a wearer's body to indicate theapproximate body location for each function. Any physical embodiment maybe used to carry out the function as long as it can perform as desiredin the location indicated and be successfully connected the otherelements in the system. Anchoring schematics have only three differentelements—force bands, connection points, and load forces. Force bandsare represented by geodesic curves. Load forces are represented by forcevectors that indicate the line of action of the load as expected in thephysical embodiment while in use. Connection points are the idealizedjunctions between force bands and the means of attaching load forces tothe network. Connection points are designated hereafter as item 548.Force bands and load forces attached to connection points communicateforces with each other and are free to rotate in all directions aboutthe connection point. The only constraint is that none of the elementsis allowed to penetrate the wearer's surface. Networks are assumed to bein equilibrium, which in some cases implies that each force band is intension.

The human surface used in the schematics presented herein is intended torepresent a typical walking baby between 12 and 24 months. Force bandsare shown to be in the approximate geodesic location of this typicaluser of absorbent diapers but it should be appreciated that surfacegeometry is somewhat different in humans at different stages of growthand maturity. Once there is knowledge of where the geodesics in theschematics reside on a target wearer, the elements for a physicalanchoring system can be sized and placed from the schematic andfabricated.

The simplest element of an anchoring system is a force band that followsan open geodesic path. FIG. 22 is a schematic of an open geodesic 549between a point 548 in the center of the front and a point 548 in thecenter of the back of the baby. Force vectors 551 and 551′ of equalmagnitude, each tangent to its respective endpoint, represent eitherload forces acting on the force band or tension from another connectedforce band.

On a frictionless, but otherwise real baby, the tensioned load bandwould automatically adjust to follow a geodesic. If the tension wereincreased, the path could change slightly as the baby surface deforms inresponse to the increased normal force in the curved areas, but the pathwould remain stable. Schematics are assumed to be at their equilibriumgeometry. It should be appreciated that in a physical embodiment of anopen force band, efforts should be made to maintain substantially equaltension at both ends in order to prevent the band from moving along thegeodesic path—i.e., sliding axially across the wearer's skin.

Load forces acting at the endpoints are anchored by support reactionsoccurring everywhere along the band where there is contact, tension, andcurvature. Therefore most of the contact area under the band isconsidered an anchoring zone. However the amount of support providedvaries within the anchoring zone. One reason is that the magnitudes ofsupport reactions vary with surface curvature. The second reason is thatthe force balance on the system requires the sum of the reactions beequal and opposite to the sum of the load forces. Thus only the reactioncomponents in the same direction as the vector sum of the load forceswill support the load. It then follows that the portions of theanchoring zone that provides the most support are those that have a highcurvature surface and are the most perpendicular to the vector sum ofthe loads of each force band. Thus in the case of the open load band inFIG. 22, most of the anchoring occurs over the hips where the surfacehas high curvature and is mostly perpendicular to the sum of the loads(the loads and their sum are all substantially parallel).

If the wearer is standing upright, most of the load forces to beanchored are substantially vertical. Therefore the valuable geodesicsfor anchoring are those that pass over surfaces with a horizontalcomponent (and therefore the surface normal has a vertical component).Some portions of the body surface can be roughly conical. These surfacescan be characterized by their “cone angle” which is the angle thatstraight lines on the surface emanating from the theoretical apex of thecone make with the vertical axis of the cone. The larger the cone anglethe flatter the cone and the larger the horizontal component of thesurface. The un-deformed surface of the naked human has geodesics thathave sufficient cone angles and curvature in places suitable foranchoring. These places tend to be at the sides of the body in the hipregion. Because the geodesics passing over such surfaces produce normalforce, the body compresses. If the body has compressibility gradients iny-direction, a roughly horizontal band with a width will tilt in at thetop and enhance the cone angle and thus the amount of anchoring that canoccur increases at a given tension. When a bone is relatively close tothe surface, an anchoring band just above the bone in the y-directionwill see a compressibility gradient in an advantageous direction and thecone angle will increase. Boney prominences that are particularly usefulin anchoring are the iliac crest (of the pelvis) and the greatertrochanter (of the femur).

By itself, this horizontal open force band may not perform usefulanchoring because the surfaces it passes over are substantiallyvertical. However, by making sure the geodesic passes over areas with agood compression gradient and thus getting the benefit of a large coneangle, the endpoints could be rotated downward and produce a greaterpotential for anchoring. With endpoints rotated down, the force bandwill possess a favorable vertical component in the front and back can bedirectly used to anchor vertical loads in the front and back. By itselfthis force band may not be stable on its geodesic because there is nomeans to couple a vertical load into the force band axially.

To overcome this, open geodesics can be combined into networks. Forinstance, FIG. 24A illustrates two mirror image open force bands 549 and549′ connected in the center of the wearer's front and back. If equaldownward loads are attached to the connection points 548, a stablesystem can be achieved. The loads can be arranged so that they splitequally between, and act tangentially on, the ends of the force bands549 and 549′. For example, this will happen if the load forces bisectthe angle between the two force bands at each connection point 548. Theover-the-hip geodesics illustrated in FIG. 24A may depend on y-directioncompressibility gradients to achieve a sufficiently vertical component.

In contrast, closed geodesics may provide self-stability. FIG. 23, forinstance, illustrates a schematic of a typical closed geodesic forceband 544 on a baby. When γ<π, the geodesic intersection (corner) is theideal connection point 548 for loads. When the load is attached to theconnection point 548, equal loads at both ends of the geodesic canoccur. The closed geodesic force band 544 may automatically shift asneeded to keep the load equally distributed to both ends of the band.

When the system anchors geodesically, the tension in the force band is afunction of load, L (the vector 551 pointing downward) and the cornerangle, γ. Tension, T, in the band equals L/(2 cos γ/2). From thisequation it can be observed that, as γ approaches 0, the tension in theband approaches L/2 (since the load splits evenly between the two ends),and is the lowest theoretically possible. As γ→π (while loaded), thetension theoretically approaches infinity. The value of γ can becontrolled by the relaxed length and spring constant of the force band.For example, γ may decrease if the relaxed length is made longer or thespring constant, k, of the force band is made smaller. Reducing k,causes the force band to stretch further for the same load. As γ getssmaller, the tension gets smaller, but the load connection point dropslower on the body. Therefore there are significant design tradeoffsbetween these parameters.

If γ<π there is potential for “slack” to form in the load band duringdynamic wear. This is because γ<π implies that a shorter closed pathexists. In dynamic wear situations, it is possible for the load to betemporarily in free flight and thus effectively reduce the load force tozero. It is then possible that with motion the force band will move tothat shorter path and slack will form. With slack present it is possiblefor the force band to be easily moved off the desired geodesic andpossibly cause it to fall off the wearer.

FIG. 25A shows two closed force bands, one band 544 to support loads inthe front and another band 544′ to support loads in the back.Independent front and back load supports can provide a stable solutionfor situations where loads originating in the front and back may besignificantly different. The force band configurations shown in FIGS.24A and 25A depict the approximate body location of four geodesics foundto be useful in anchoring systems. The exact locations of the geodesicsvary somewhat between groups at different stages of growth and maturityand between individual wearers within groups.

With knowledge of the basic principles of geodesics and the locations ofuseful body geodesics it can be appreciated that many differenttheoretical anchoring configurations can be created from force bands,connection points, and load forces toward particular design objectives.These schematics can be embodied digitally or physically and tested onvirtual or real wearers as anchoring systems attached to a coreassembly.

In anchoring system schematics, load forces are depicted in the figuresonly by their connection points and directions. By convention theschematic provides connection points on the anchoring system thatanticipate matching connections on the core assembly; therefore makingit unnecessary to specify the load forces further. A brief discussionfollows of how some of the schematic anchoring configurationscontemplated by the present invention are theoretically believed towork.

With regard to FIGS. 24A-33C, the “A” figures are the functionalschematic, the “B” figures are the physical embodiment of the functionalmodel, and the “C” figures are the physical embodiment within anabsorbent article. As such, the force bands referred to hereafterrepresent the functional model for anchoring bands and LDEs of thephysical anchoring system.

A suitable configuration of an anchoring system constructed inaccordance with the present invention is shown in FIG. 24A. The FIG. 24Aconfiguration may comprise two over-the-hip force bands 549, 549′ withcentered load connections, front and back. This is the simplest possiblegeodesic anchoring system. Anchoring occurs primarily by the normalforce generated over the hips 500. The configuration is characterized byan angle, γ, at connection point 548 which is defined exactly as in FIG.23. As γ→π this two geodesic system approaches a single closed geodesic.As described earlier in regard to a closed geodesic, there is arelationship between tension, load, and γ. T=L/(2 cos γ/2). An infinitetension causes γ to approach π with a non-zero load.

However, the configuration of FIG. 24A can be subject to twoinstabilities described previously. For example, in a frictionlesssystem, unequal front and back loads may cause the system to rotate(e.g., from the front going down and back going up or vice-versa)generally about the x-axis (shown in FIG. 8). In a physical embodiment,friction will permit a difference in front and back loads. As such, insome embodiments, the tension in the anchoring bands can be increased byincreasing γ. The increase in γ will increase the tension in theanchoring bands thereby increasing the friction which can widen thetolerance for unequal loads. However, friction is not always dependablein dynamic situations. As such, in some embodiments, load balancing canbe achieved by separately adjusting γ between front and back by changingthe elevation of the connection points 548. This approach may beparticularly useful if the ratio of the front and back loads remainsfairly constant. Tension would be the same front and back when thefollowing condition is met.$\frac{L_{1}}{L_{2}} = \frac{\cos( {\gamma_{1}/2} )}{\cos( {\gamma_{2}/2} )}$

Note that changing γ can change the geodesic path. Another example of aninstability comes from slack (also described previously) in a dynamicsystem. The smaller γ is, the longer the total path length of thegeodesics, and the larger the potential slack. Potential slack has anadvantage in pant products because if γ is low enough, the slack can beenough to allow the pant to be pulled over the buttocks and hips withoutrequiring the anchoring bands to stretch. Of course, the downside ofslack is instability. Where γ smaller, stability can be obtained byproviding low-force elastic structures designed to simply keep thegeodesics in place in the event of slack-caused a dynamic excursion. Inthe present invention an elastic biaxial stretch outer cover can servethe role. For stand-alone anchoring systems, the following configurationcan be used.

In some embodiments, an anchoring system constructed in accordance withthe present invention may be configured as shown in FIG. 29A. The FIG.29A configuration may comprise two over-the-hip force bands 549, 549′with centered load connections 548, front and back with an elasticstabilizing band 561. This configuration takes care of the stabilityproblem of the anchoring system of FIG. 24A configuration by adding alow force closed elastic geodesic to simply maintain the location of theanchoring bands in the event they are slack during a dynamic excursion.Stabilizing bands are joined to the geodesic force bands; however, theremay be no significant force balance to be considered at the attachmentpoints. In some embodiments, for example, in a pant, the elasticstabilizing band 561 can easily stretch when the pant is pulled up, butit would not have to carry a large portion if any of anchoring loadduring wear.

In some embodiments an anchoring system constructed in accordance withthe present invention may be configured as shown in FIG. 32A. Theanchoring system of FIG. 32A may comprise two open geodesic stabilizingbands 561, 561′ instead of the single closed geodesic of FIG. 29A. Thestabilizing bands 561 and 561′ may be joined to the force bands 549 and549′; however, no significant force balance may need to be considered.Both stabilizing band configurations of FIGS. 29A and 32A can work forstand-alone anchoring systems.

In some embodiments, an anchoring system constructed in accordance withthe present invention may be configured as shown in FIG. 25A. The FIG.25A configuration may comprise two closed force bands 544, 544′ andcentered load connections 548, front and back. The closed geodesics areanchored in the same general area 500 over the hips as the other systemsdescribed thus far. This system is very stable particularly if operatingwith little or no slack. It can be particularly effective where thearticle is a side-fastened taped diaper. In some cases the center loadconnection points 548 may be too low on the core assembly (as may be thecase for any centered load connections). The load connection points 548can be raised using the configuration shown in FIG. 26A.

In some embodiments, the load connection points 548 can be configured toprovide two load connection points 548A and 548B that are higher andoutboard of the original location of the single connection point 548(shown in FIG. 25A). FIGS. 34 and 35 show how the two configurationsprovide equivalent anchoring with different load connections. FIG. 34represents one of the closed force bands 544 with a center loadconnection 548. The force band is “cut” by a horizontal line 501 abovethe original connection point 548 and below the portion of the forceband 544 where normal support reactions occur 500 (shown in FIG. 25A).This creates two new connection points 548A and 548B. In FIG. 35, a newsingle geodesic 550 reconnects the force band 544 at the new connectionpoints 548A and 548B and provides the means to resolve the horizontalcomponents of the tension in the remainder of the original force band544. The vertical load force may be split into two halves and moved tothe two new connection points 548A and 548B. At each connection point548A and 548B, the force band 544 and new load force add vectorially sothat the portion of force band 544 above the “cut” line 501 mayexperience the same axial tension as before. Any load connection pointcan be reconfigured as long as the parts of the geodesic where theanchoring reactions take place are unchanged and they remain axiallyloaded with the same tension.

In some embodiments, an anchoring system constructed in accordance withthe present invention may be configured as shown in FIGS. 28A-28C. Asshown in FIG. 28A, the anchoring system may comprise two over-the-hipforce bands 549, 549′ similar to the FIG. 24A configuration but withraised connection points 548A, 548B, 548C, and 548D. The connectionpoints 548A and 548B may be disposed at the front of a wearer while theconnection points 548C and 548D may be disposed at the back of a wearer,when the anchoring system is in use. The load connection points may bederived from the FIG. 24A configuration in the same way that the FIG.26A configuration was derived from the FIG. 25A configuration.

In some embodiments, an anchoring system constructed in accordance withthe present invention may be configured as shown in FIGS. 30A, 30B, and31A-31C. As shown in FIGS. 30A and 31A in some embodiments, an anchoringsystem may comprise portions of the open and closed geodesicconfigurations discussed with regard to FIGS. 24A and 25A. For example,an anchoring system may comprise two and four load connection pointversions of a hybrid of the closed and open geodesic configurations ofFIGS. 24A and 25A. These configurations have 5 and 7 open geodesic forcebands, respectively. The creation of the extra connection points cancreate two additional open geodesic force bands (550 and 550′) in FIG.31A. They are distinguished from previous configurations bypre-tensioned force bands made up of an upper open force band 546 in theback and two front open force bands 544, 544′. Pre-tensioning (i.e.tension caused by the application process, not by load forces) providesstability for the force bands and a tension bias that improves geometricanchoring.

Once loads are applied (as illustrated), the geodesics that meet at theside connection points form angles that balance the forces in 546, 545′and 544′. The same can be true for the opposite side of the body. Thusthe geodesic paths of this configuration will be slightly different thangeodesics that run continuously through this area of the body such asthose of FIGS. 24A and 25A. There are many practical advantages to thisconfiguration. As in most configurations, anchoring occurs primarily inthe hip regions.

In some embodiments, an anchoring system constructed in accordance withthe present invention may be configured as shown in FIGS. 33A-33C. Asshown, the FIG. 33A configuration may comprise a single pre-tensionedcircumference made up of four open force bands 570, 571, 572, 573 and azone 574, 574′ of distributed load force over each hip. The schematicsymbol for a distributed load force is introduced in this figure. Theidea behind this configuration is to leverage the geometric anchoringmode. This load distribution is not straight-forward to physicallyembody because there are no loads nor pathways to loads directly belowthis area. In practice, a structure is provided that can take loadsdiagonally from the front and back, balance the horizontal componentsand distribute the vertical components to the geodesic. Such loads wouldcause the geodesic to move off its true geodesic path as has beenpreviously described. FIG. 33B shows a structure that approximates thisbehavior.

A small amount of stretch can help geodesic stability and is hence oftendesirable. On the other hand, increasing the length of the force bandswill change the geometry and run the risk that the new geometry may notfall on desirable geodesics. There are many ways to configure stretch inthe anchoring system. One skilled in the art will recognize that itwould be useful to test theoretical configurations incorporating stretchprior to engineering an anchoring configuration into a complete product.Force bands can be divided into sections with differing stretchproperties. Often the same amount of stretch in one section can have alower impact on geodesic geometry than in another.

If an anatomically accurate digital or physical mannequin is available,schematics can be literally studied with systems of strings, springs,and load weights. Each force band is simulated by a string in serieswith a steel spring with a known constant. Simple ways are devised toconnect simulated force bands together. Loads can be simulated byhanging weights. This allows the geodesic stability response of thenetwork to be studied and optimized for the stretch placement andextension properties. Since stretch is often employed to improve sizerange, this too can be easily studied if different size mannequins or“virtual wearers” are available.

In the case of anchoring systems implemented into taped diapers, it isusually possible to select a force band section for stretch that willhave a minimum impact on geodesic geometry. For example, in the FIG. 31Aconfiguration the force bands 544 and 544′ between each side connectionpoint and the front is a good place for stretch. The connection point onthe core could literally be the landing zone for a fastener. A landingzone located along the connecting geodesic across the core could providesufficient rigidity so that the weight of the core could be correctlydirected to the stretch anchoring band.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference, however the citation ofany document is not construed as an admission that it is prior art withrespect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It should beapparent that combinations of such embodiments and features are possibleand can result in executions within the scope of this invention. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A disposable wearable absorbent article comprising an absorbent corewith an absorbent core end, an anchoring system configured to anchor theabsorbent core to a wearer, and a waist cover that covers at least aportion of the absorbent core end.
 2. The disposable wearable absorbentarticle of claim 1, wherein the waist cover extends laterally across thearticle from a first side edge of the article to a second side edge ofthe article.
 3. The disposable wearable absorbent article of claim 1,wherein a lateral width of the waist cover is about equal to a lateralwidth of the absorbent core.
 4. The disposable wearable absorbentarticle of claim 1, wherein the waist cover is formed by a discretewaistband attached to an inner surface of the article.
 5. The disposablewearable absorbent article of claim 1, wherein the waist cover isstretchable in a lateral direction with respect to the article.
 6. Thedisposable wearable absorbent article of claim 1, wherein the waistcover is stretchable in a longitudinal direction with respect to thearticle.
 7. The disposable wearable absorbent article of claim 1,wherein the waist cover is elastic.
 8. The disposable wearable articleof claim 1, including an outer cover, wherein the absorbent core isbonded to the outer cover with one or more bonds that together cover aparticular bond area that is less than 20 square centimeters.
 9. Thedisposable wearable article of claim 8, wherein the one or more bondsare a single bond area.
 10. The disposable wearable article of claim 1,including an outer cover, wherein the absorbent core covers a particularcore area and the absorbent core is bonded to the outer cover with oneor more bonds that together cover a particular bond area that is lessthan 20 percent of the particular core area.
 11. The disposable wearablearticle of claim 10, wherein the one or more bonds are a single bondarea.
 12. The disposable wearable article of claim 1, including an outercover, wherein the absorbent core is bonded to the outer cover only in alongitudinally central region of the absorbent core.
 13. The disposablewearable article of claim 1, including an outer cover, wherein theabsorbent core is bonded to the outer cover only in a laterally centralregion of the absorbent core.
 14. The disposable wearable article ofclaim 1, including an outer cover, wherein the absorbent core is bondedto the outer cover with a bond that is longitudinally elongated.
 15. Thedisposable wearable article of claim 1, including an outer cover,wherein the absorbent core is bonded to the outer cover with a bond thatextends over substantially all of a longitudinal length of the absorbentcore.
 16. The disposable wearable article of claim 1, wherein at leastpart of the anchoring system is structurally associated with the waistcover.
 17. The disposable wearable article of claim 16, wherein at leastpart of the anchoring system is integral with the waist cover.
 18. Thedisposable wearable absorbent article of claim 17, wherein the anchoringsystem includes an anchoring band, and at least a portion of theanchoring band is integral with the waist cover.
 19. The disposablewearable absorbent article of claim 17, wherein the anchoring systemincludes a circumferential anchoring member, and at least a portion ofthe circumferential anchoring member is integral with the waist cover.20. The disposable wearable absorbent article of claim 17, wherein theanchoring system includes a load distribution element joined to theabsorbent core, and at least a portion of the load distribution elementis integral with the waist cover.
 21. The disposable wearable absorbentarticle of claim 16, wherein the anchoring system includes an anchoringband, and at least a portion of the anchoring band is attached to thewaist cover.
 22. The disposable wearable absorbent article of claim 16,including an outer cover, wherein the anchoring system includes ananchoring band, at least a portion of the anchoring band is attached tothe waist band, and at least a portion of the anchoring band is attachedto the outer cover.
 23. The disposable wearable absorbent article ofclaim 16, wherein the anchoring system includes a circumferentialanchoring member, and at least a portion of the circumferentialanchoring member is attached to the waist cover.
 24. The disposablewearable absorbent article of claim 16, including an outer cover,wherein the anchoring system includes a circumferential anchoringmember, at least a portion of the circumferential anchoring member isattached to the waist band, and at least a portion of thecircumferential anchoring member is attached to the outer cover.
 25. Thedisposable wearable absorbent article of claim 16, wherein the anchoringsystem includes a load distribution element, and at least a portion ofthe load distribution element is attached to the waist cover.
 26. Thedisposable wearable absorbent article of claim 1, including an absorbentcore assembly, which includes the absorbent core, wherein the anchoringsystem is configured to anchor the absorbent core assembly to a wearer.27. The disposable wearable absorbent article of claim 1, including anouter cover, wherein the outer cover is stretchable in at least onedirection.
 28. The disposable wearable absorbent article of claim 1,including an outer cover, wherein the outer cover is a zero-strainlaminate.
 29. The disposable wearable absorbent article of claim 1,including an outer cover, wherein the article is a fastenable disposablewearable absorbent article.
 30. The disposable wearable absorbentarticle of claim 1, including an outer cover, wherein the article is apant-type disposable wearable absorbent article.